INTERNATIONAL MULTIDISCIPLINARY JOURNAL FOR
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DEVELOPMENT OF CONSUMPTION NORMS FOR KD COMPONENT PARTS AND
PACKAGING MATERIALS FOR THE B-CAR (ONIX) VEHICLE
Umidjon Karimov
Assistant Andijan State Technical Institute
Abstract: Component cost analysis
involves optimizing the use of materials, time, and energy
in the development of models and components. Parts for expendable materials and the amount
of resources ( e.g. , metal , plastic ) and their value evaluation . This in step the following
calculation possible :
- Every one component part for necessary materials amount .
- Manufacturing release in the process usable energy and time .
Complementary parts spending analysis in doing construction documents working exit very
important .
Keywords:
B-Car, bolter, material, raw material, production, optimization, consumption,
efficiency,
Developing consumption standards for components and packaging materials for the B-CAR
(ONIX) vehicle is an important step in optimizing production processes, reducing costs, and
increasing material efficiency. This process covers all stages, from vehicle production to
product transportation.
When calculating the consumption of components for a B-CAR (ONIX) car, the dimensions,
material type, and manufacturing process of each component are taken into account.
Components include mechanical parts, electronic parts, and structural parts. As an example of
calculating the consumption rates for components, if the size of a steel sheet is 2 m× 1 mand the
total surface area of the material required for the car div 10 m²is, the number of steel sheets
required is:
Po'number of lists=
=
5lists
- An additional 10% material allowance should be included in the bending or forming process
of a steel sheet. Therefore, the total material quantity is:
10m2 ×
1.1
=
11m2
Calculation of Packaging Material Consumption Rates
Packaging materials
are materials needed for the transportation and storage of manufactured
automotive parts or assemblies. Packaging materials include:
- Packaging boxes (cardboard boxes, plastic containers, wooden boxes).
- Cushioning materials (polyethylene, scotch tape, cotton, or other shock-absorbing materials).
- Packaging materials (plastic wrap, foil, etc.)
When calculating the consumption of packaging materials, the following should be taken into
account:
Packaging and packing volume of parts - how we will wrap and pack each part or component.
For example, if 10 parts fit in one box, it is necessary to calculate their total volume and the
amount of material required.
Packaging efficiency - it is important to calculate the packaging efficiency when calculating the
required amount of packaging materials. It shows how optimal the packaging is and the
possibilities for reducing material waste. For example, if a box holds 10 parts and 0.5
m²cardboard is used for packaging, the amount of cardboard required for 100 parts is:
Cardboard material = 100 pieces × 0.5 m
2
= 50 m
2
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If softening materials (e.g. polyethylene) are used for each part 0.1 m², the amount of
polyethylene required for 100 parts is:
Polyethylene material = 100 pieces × 0.1 m
2
= 10 m
2
Table 3.4
Stages of Developing Consumption Norms
Group
number
Stage name
Things to do
Result / document
1.
Formulation of the
technical task
Modeling, technical requirements,
operating conditions are studied
Technical assignment
2.
Making
a
preliminary list of
details
The composition is determined by
chassis, engine, and transmission.
Specification project
3.
List of analog
products
Consumption
standards
and
technologies in similar models are
studied.
Analytical report
4.
Experience-
gathering
and
testing
Actual costs are determined through
collection in a pilot series
Test reports
5.
Regulatory
calculations
The weight of the parts, material
consumption,
and
losses
are
calculated.
Consumption norms
(calculation tables)
6.
Expertise
and
approval
It is confirmed by technologists and
economists.
Approved norm
7.
Input
into
the
information
system
It is included in the ERP or PLM
system.
Digital database
Table 3.5
Time allocation for the stages of developing cost estimates
Stage
Time share (%)
Technical assignment
10
List of details
10
Analysis of analogues
15
Experience-gathering and testing
25
Regulatory calculations
20
Expertise and approval
10
Input into the information system
10
BOM (Bill of Materials) is also widely used in developing consumption standards.
di. BOM (Bill of Materials) is a document that lists all the materials, components, parts, and
components used in the development and assembly of a product. BOM is a key component of
the manufacturing process because it helps to achieve the following goals:
- Determining the materials needed for production.
- Calculation of parts consumption.
- Planning of production and assembly processes.
- Inventory management.
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- Cost control.
- Ensuring product quality.
During the BOM creation process, details (name, quantity, dimensions, codes, and other
necessary information) of each component or material are provided.
The steps for creating a BOM are detailed in the table below (for the Chassis part).
Table 3.6
Complementary Parts Spending Analysis To do
is to product or the system working in the
release usable all component quantity , quality , price of parts ( components , materials , details )
and them working in the output spending to study
is a process . Complementary of parts
spending analysis to do , to work release efficiency increase , expenses reduce inventory
management and quality to provide for important . Complementary parts spending analysis to
do one how many goals They are available . as follows :
1. Expenses reduce — product price reduce , resources effective use .
2. Materials and parts optimization — work release for necessary was
materials amount
correct mark .
3. Quality control — the quality of components and their compatibility.
4. Improving the production process - optimizing technologies and processes, increasing
production efficiency.
5. Inventory and supply chain management — ensuring timely delivery of needed parts,
reducing the output of excess materials and parts.
KD (Knocked Down) components are all the parts needed to assemble a car, which are
delivered to the assembly site and transformed into a complete car during the assembly process.
These parts are:
1. Mechanical parts - engine, transmission, wheels, chassis and suspension system parts.
2. Electronic components - wiring system, sensors, control module.
3. Body and exterior parts - doors, window frames, panels, div parts.
4. Interior parts - seats, panels, control system, air conditioning and other systems.
5. Fasteners - screws, nuts, glue and connectors.
When calculating the consumption rates for each detail:
- Weight and dimensions:
The weight and dimensions of each detail are important in
determining the consumption of materials.
-
Thickness - the required thickness for the material (steel, aluminum, plastic, etc.)
- Body steel sheets - 2 m²steel material, thickness 1 mm, weight 6.28 kg( 1 m²= 6.28 kg).
-
Aluminum parts- 0.5 m²aluminum panel, weight 2.2 kg( 1 m²= 4.4 kg).
Materials required to assemble 100 B-CAR (Tracker) vehicles:
- Steel materials - 6.28 kg/m² x 100 m²= 628 kg.
-
Aluminum materials - 2.2 kg/m² x 50 m² = 110 kg.
Packaging Material Consumption
is the process of calculating the quantity and cost of
materials used in the packaging of a product, ensuring that they are used in an efficient and
Part code
Part name
Quantity
Unity
Consumption
rate
SH-001
Frame
1
piece
1
SH-002
Front suspension 1
Collection
1
SH-003
Rear suspension
1
Collection
1
SH-004
Wheel (front)
2
piece
2
SH-005
Wheel (rear)
2
piece
2
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eISSN :2394-6334 https://www.ijmrd.in/index.php/imjrd Volume 12, issue 08 (2025)
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cost-effective manner. Efficient packaging material consumption is essential for reducing the
overall costs of production and distribution processes, while ensuring product safety and quality.
Packaging materials can be different, for example: cardboard, polyethylene, plastic, glass,
aluminum, air bubbles, foamed materials and other materials. Each of them is selected
depending on the type of product, packaging method and storage, transportation conditions.
There are necessary calculations and methods to optimize consumption rates and properly use
materials.
When optimizing the consumption of packaging materials and KD components, it is necessary
to consider the following:
-
The shape and size of the packaging materials should be designed to optimize transportation.
For large parts, special packaging methods will be developed.
-
Packaging materials should be made from environmentally friendly and recyclable materials.
This is an important environmental factor in car manufacturing.
-
The consumption rate for packaging materials and components should reduce production costs.
Packing materials needed for each car (for example, for 100 cars):
-
Carton for steel panels: 100 pieces x 0.2 m³ = 20 m³ carton.
-
Plastic packaging for electronics parts: 50 pieces x 1 m² = 50 m² of plastic.
- Silicone protection for window frames : 100 pieces x 2 m = 200 m of silicone.
References:
1. Schwartz, GV (2021), *Automobile Production Technology*. - Tashkent: "Uzbekistan"
Publishing House.
- Theoretical and practical information on technological processes, raw material consumption
and production optimization in the automotive industry.
2. Gulomov, I. & Tursunov, A. (2019), *Optimization of production processes and resource
management*. - Tashkent: "O'zbekiston Yangi Avlod" publishing house.
- Scientific and technical analyses of production processes, raw material consumption and
resource management.
3. Yusufov, AK (2020), *Increasing labor productivity and efficiency in the automotive
industry*. - Samarkand: Samarkand State University.
- Modern approaches and methodologies for automotive production and efficient use of
resources.
4. Standards Agency of the Republic of Uzbekistan (2023), *State standards for raw materials
and materials used in the automotive industry*. - Tashkent.
- Official state standards and regulations for materials used in the automotive industry, raw
material consumption, and quality standards.
5. Rudnitsky, VV, & Lomov, SS (2018), *Materials Selection and Design Solutions:
Technological Aspects in Automotive and Industrial Systems*. - Moscow: Mechanical
Engineering Publishing House.
