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Cost Comparison Rev 2 LQ

This document compares the consumable and maintenance costs of clinching, riveting, and spot welding machines for fastening sheet metal over 100,000 joints. It finds that the total cost to operate a clinching machine for 100,000 joints is $936.43, compared to $1273.58 for a riveting machine and $1517.83 for a spot welding machine. The document provides a breakdown of the individual cost components that make up the total, such as electricity costs, tooling costs, labor costs, and machine costs.

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B.Harish Kumar
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102 views

Cost Comparison Rev 2 LQ

This document compares the consumable and maintenance costs of clinching, riveting, and spot welding machines for fastening sheet metal over 100,000 joints. It finds that the total cost to operate a clinching machine for 100,000 joints is $936.43, compared to $1273.58 for a riveting machine and $1517.83 for a spot welding machine. The document provides a breakdown of the individual cost components that make up the total, such as electricity costs, tooling costs, labor costs, and machine costs.

Uploaded by

B.Harish Kumar
Copyright
© Attribution Non-Commercial (BY-NC)
We take content rights seriously. If you suspect this is your content, claim it here.
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Download as PDF, TXT or read online on Scribd
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This report explores consumable and

maintenance costs associated with


these three fastening processes.

Cost to operate a NORLOK machine for


100,000 joints:
$ 936.43

Cost Analysis Cost to operate a Rivet machine for


100,000 joints:
Clinching vs. Spot Welding $1273.58
and Riveting.
Cost to operate a Spot welder for
100,000 joints:
$1517.83
NORLOK Clinching machines are clean,
inexpensive, and reliable equipment for
fastening sheet metal. This revolutionary
process is rapidly becoming an industry
standard in the HVAC, automotive,
housing, and manufacturing industries.
Clinching offers versatility, flexibility, and
repeatability, which earns great respect in
the field of sheet metal fastening.

A NORLOK clinching machine uses no


rivets, bolts or fasteners, and fastens
prepainted, dissimilar and other coated
materials with very low operating costs
compared to resistance spot welders and
riveting type machines
COST ANALYSIS OF CLINCHING VS. RIVETING AND SPOT WELDING

• For the purpose of this report an assumption of 0.05 cents per kilowatt hour (kW-hr)
has been made for machine electricity consumption.
• Material fastened is assumed to be 0.048” plain mild steel.
• Labor burden has been calculated at $35.00 / hr for maintenance employees and
$17.50 / hr machine operators
• For this report the cost of clinching was calculated using Norlok’s pneumatic
powered Surelok machine @ 0.6 cu ft / joint [60 cycles/ min]. RSW was calculated
using a 50kVA transgun welder with simple controller [30 cycles/ min]. For Riveting,
a stand alone automatic feed riveter with a ½ hp drive motor [120 cycles/ min].

Clinching Machine

• Machine cycle at approx. 60 cycles/ min.


• Clinching machine, tooling lasts from 250,000 – 1,000,000 hits.
• At 250,000 life, tooling cost is approx. $180.00 per 100,000 Joints.
• Electricity requirement to produce 100,000 joints is 106.30kW-hr (approx. ($5.32).
• Machine costs range between $9,000.00 - $10,000.00 (approx. $US).
• Labor of maintenance personnel to replace tooling every 250,000 joints is estimated
at 0.5 hr (assume 0.2 hr every 100,000).
• 1 hr associated to maintenance of machine labor per 100,000 joints.

Riveting Machine

• Machine operating at approx.120 cycles/min.


• Cost of replacing tooling every 5000 hits (estimated avg.). @ $35.00 per driver
replacement ($700.00 per 100,000 hits).
• Assuming a cost of $ 0.005 per rivet avg. ($500.00 per 100,000).
• Electricity requirements for Riveting machine for 100,000 hits is 10.63kW-hr
(approx. $0.532).
• Machine cost range between $9,000.00 -$10,000.00 (approx. $US).
• Labor of maintenance personnel to replace tooling every 100,000 joints is estimated
at 2 hrs (.1 hr to replace driver. Every 5000 joints).
• 2 hrs associated to maintenance of machine labor per 100,000 joints.

RSW (Resistance Spot Welding)

• Machine operating at approx. 30 cycles/min.


• Welding tips must be dressed approximately every 1000 joints to a maximum of 5
dressings per tip. At $2.00 / tip, cost for 100,000 joints is $80.00.
• Electricity requirements to produce 100,000 joints is 155.55 kW-hr (approx. $7.785).
• Cooling water cost is approx. $2.822 per 100,000 joints.
• Costs associated to compressed air use / 100,000 is 1.26 kW-hr (approx. $0.06)
• Machine costs range between $9,000.00 -$10,000.00 (approx. $US).
• Labor of maintenance personnel to replace and dress tooling every 100,000 joints is
estimated at 10 hrs (.08 hr to replace tip + .02 hr to dress tip. Every 1000 joints).
• 3 hrs associated to maintenance of machine labor per 100,000 joints.
Cost Comparison Table

Clinching Riveting RSW

Cost of Machine $US 1 $10,000.00 $10,000.00 $10,000.00

Electricity requirements for 100,000 joints


Direct Electricity kW-hr 2 Nil 10.63 kW-hr 155.55 kW-hr
Indirect Electricity kW-hr 3 106.30 kW-hr Nil 1.26 kW-hr

Operating cost for 100,000 joints


Depreciation of machine 4 $20.00 $20.00 $20.00
Cost of Electricity 5 $5.32 $0.53 $7.79
Cooling Water 6 Nil Nil $2.82
Cost of tooling Maintenance 7 $10.00 $70.00 $350.00
Tool Cost 8 $360.00 $350.00 $40.00
Maintenance of Machine 9 $55.00 $90.00 $125.00
Cost of Fastener Nil $500.00 Nil
Labor 10 $486.11 $243.05 $972.22

Total cost $936.43 $1273.58 $1517.83

1
Average machine cost of equivalent capacity.
2
Not including premiums for peak demands (a consideration for RSW)
3
Cost to run air compressor disregarding any loss due to inefficiencies, or cost to
install/maintain pipes.
4
Estimating a machine life expectancy of 50 million cycles
5
Calculated at 0.05 kW-hr, assumption for average electricity services not including costs
to install/maintain service.
6
Costs not including install/maintain of piping or environmental concerns.
7
Calculated at $35.00 / hr including labor to replace and/or dress tooling.
8
Cost of tooling replacement (punch, die, weld tips, drivers)
9
Including cost of parts and maintenance labor.
10
Calculated at $17.50 / hr average machine operator wage (skilled operator).
Letterlok 3000 Return
Fastener.

Heavy Duty Surelok Custom equipment designed


Available in 18 and to suit any application.
24 inch throats.

Watson Portable Machines


Medium duty, Heavy Duty
and many specials available.

Letterlok 4000 for the


sign industry.

Distributed by:

Standard Surelok
Available in 18 & 25 inch
Fitting Machine for throats.
the HVAC Industry.

Norlok Technology Inc.


26 Adams Blvd, Brantford, Ontario, Canada, N3S 7V2
ph 519 759-5896 fx 519 759-2948 – email nlmail@norlok.com web www.norlok.com

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