FSAE Cost Report Preparation Checklist
- Team Name: _______________
- Competition: _______________
- Cost Report Due Date: _______________
- Cost Officer(s): _______________
- Vehicle Target Cost: $_______________
1. Pre-Report Setup & Planning
| Task |
Assigned Member |
Due Date |
Status |
Notes |
| Download Cost Supplement from FSAEonline |
|
|
⬜ Not Started ⬜ In Progress ✅ Complete |
|
| Download Cost Module Guide |
|
|
⬜ Not Started ⬜ In Progress ✅ Complete |
|
| Access Online Cost Module on FSAEonline |
|
|
⬜ Not Started ⬜ In Progress ✅ Complete |
|
| Review Cost Tables and Catalogs |
|
|
⬜ Not Started ⬜ In Progress ✅ Complete |
|
| Set up team organization for cost report |
|
|
⬜ Not Started ⬜ In Progress ✅ Complete |
|
| Create timeline and deadlines |
|
|
⬜ Not Started ⬜ In Progress ✅ Complete |
|
2. Bill of Materials (BOM) Organization
| Task |
Assigned Member |
Due Date |
Status |
Notes |
| Create assembly tree structure |
|
|
⬜ Not Started ⬜ In Progress ✅ Complete |
|
| Organize parts by 8 main systems |
|
|
⬜ Not Started ⬜ In Progress ✅ Complete |
|
| Set up sub-assemblies per system |
|
|
⬜ Not Started ⬜ In Progress ✅ Complete |
|
| Assign part numbers to all components |
|
|
⬜ Not Started ⬜ In Progress ✅ Complete |
|
| Create master parts list |
|
|
⬜ Not Started ⬜ In Progress ✅ Complete |
|
3. System 1: Frame & Body
| Task |
Assigned Member |
Due Date |
Status |
Notes |
| Frame tubes and joints BOM |
|
|
⬜ Not Started ⬜ In Progress ✅ Complete |
|
| Body panels and mounting hardware |
|
|
⬜ Not Started ⬜ In Progress ✅ Complete |
|
| Roll hoop and impact attenuator |
|
|
⬜ Not Started ⬜ In Progress ✅ Complete |
|
| Seat and restraint system |
|
|
⬜ Not Started ⬜ In Progress ✅ Complete |
|
| Cost all materials from catalog |
|
|
⬜ Not Started ⬜ In Progress ✅ Complete |
|
| Cost all manufacturing processes |
|
|
⬜ Not Started ⬜ In Progress ✅ Complete |
|
| Create detailed drawings |
|
|
⬜ Not Started ⬜ In Progress ✅ Complete |
|
| Calculate tooling costs (if applicable) |
|
|
⬜ Not Started ⬜ In Progress ✅ Complete |
|
4. System 2: Suspension
| Task |
Assigned Member |
Due Date |
Status |
Notes |
| Suspension arms and uprights BOM |
|
|
⬜ Not Started ⬜ In Progress ✅ Complete |
|
| Springs and dampers |
|
|
⬜ Not Started ⬜ In Progress ✅ Complete |
|
| Bearings and bushings |
|
|
⬜ Not Started ⬜ In Progress ✅ Complete |
|
| Anti-roll bars and linkages |
|
|
⬜ Not Started ⬜ In Progress ✅ Complete |
|
| Cost all materials from catalog |
|
|
⬜ Not Started ⬜ In Progress ✅ Complete |
|
| Cost all manufacturing processes |
|
|
⬜ Not Started ⬜ In Progress ✅ Complete |
|
| Create detailed drawings |
|
|
⬜ Not Started ⬜ In Progress ✅ Complete |
|
| Calculate assembly costs |
|
|
⬜ Not Started ⬜ In Progress ✅ Complete |
|
5. System 3: Drivetrain
| Task |
Assigned Member |
Due Date |
Status |
Notes |
| Engine/motor and mounting BOM |
|
|
⬜ Not Started ⬜ In Progress ✅ Complete |
|
| Transmission and differential |
|
|
⬜ Not Started ⬜ In Progress ✅ Complete |
|
| Driveshafts and CV joints |
|
|
⬜ Not Started ⬜ In Progress ✅ Complete |
|
| Chain/belt drive components |
|
|
⬜ Not Started ⬜ In Progress ✅ Complete |
|
| Cost all materials from catalog |
|
|
⬜ Not Started ⬜ In Progress ✅ Complete |
|
| Cost all manufacturing processes |
|
|
⬜ Not Started ⬜ In Progress ✅ Complete |
|
| Create detailed drawings |
|
|
⬜ Not Started ⬜ In Progress ✅ Complete |
|
6. System 4: Wheels & Tires
| Task |
Assigned Member |
Due Date |
Status |
Notes |
| Wheels and hubs BOM |
|
|
⬜ Not Started ⬜ In Progress ✅ Complete |
|
| Tires specification |
|
|
⬜ Not Started ⬜ In Progress ✅ Complete |
|
| Wheel bearings and hardware |
|
|
⬜ Not Started ⬜ In Progress ✅ Complete |
|
| Brake rotors and mounting |
|
|
⬜ Not Started ⬜ In Progress ✅ Complete |
|
| Cost all materials from catalog |
|
|
⬜ Not Started ⬜ In Progress ✅ Complete |
|
| Create detailed drawings |
|
|
⬜ Not Started ⬜ In Progress ✅ Complete |
|
7. System 5: Brakes
| Task |
Assigned Member |
Due Date |
Status |
Notes |
| Brake calipers and pistons BOM |
|
|
⬜ Not Started ⬜ In Progress ✅ Complete |
|
| Master cylinder and pedal assembly |
|
|
⬜ Not Started ⬜ In Progress ✅ Complete |
|
| Brake lines and fittings |
|
|
⬜ Not Started ⬜ In Progress ✅ Complete |
|
| Brake pads and hardware |
|
|
⬜ Not Started ⬜ In Progress ✅ Complete |
|
| Cost all materials from catalog |
|
|
⬜ Not Started ⬜ In Progress ✅ Complete |
|
| Cost all manufacturing processes |
|
|
⬜ Not Started ⬜ In Progress ✅ Complete |
|
| Create detailed drawings |
|
|
⬜ Not Started ⬜ In Progress ✅ Complete |
|
8. System 6: Steering
| Task |
Assigned Member |
Due Date |
Status |
Notes |
| Steering rack and column BOM |
|
|
⬜ Not Started ⬜ In Progress ✅ Complete |
|
| Steering wheel and controls |
|
|
⬜ Not Started ⬜ In Progress ✅ Complete |
|
| Tie rods and steering arms |
|
|
⬜ Not Started ⬜ In Progress ✅ Complete |
|
| Universal joints and bearings |
|
|
⬜ Not Started ⬜ In Progress ✅ Complete |
|
| Cost all materials from catalog |
|
|
⬜ Not Started ⬜ In Progress ✅ Complete |
|
| Cost all manufacturing processes |
|
|
⬜ Not Started ⬜ In Progress ✅ Complete |
|
| Create detailed drawings |
|
|
⬜ Not Started ⬜ In Progress ✅ Complete |
|
9. System 7: Electronics
| Task |
Assigned Member |
Due Date |
Status |
Notes |
| ECU and sensors BOM |
|
|
⬜ Not Started ⬜ In Progress ✅ Complete |
|
| Wiring harness and connectors |
|
|
⬜ Not Started ⬜ In Progress ✅ Complete |
|
| PCB design and components |
|
|
⬜ Not Started ⬜ In Progress ✅ Complete |
|
| Battery and charging system |
|
|
⬜ Not Started ⬜ In Progress ✅ Complete |
|
| Data acquisition components |
|
|
⬜ Not Started ⬜ In Progress ✅ Complete |
|
| Cost all materials from catalog |
|
|
⬜ Not Started ⬜ In Progress ✅ Complete |
|
| Cost PCB manufacturing processes |
|
|
⬜ Not Started ⬜ In Progress ✅ Complete |
|
| Create wiring diagrams |
|
|
⬜ Not Started ⬜ In Progress ✅ Complete |
|
| Calculate assembly time |
|
|
⬜ Not Started ⬜ In Progress ✅ Complete |
|
10. System 8: Miscellaneous
| Task |
Assigned Member |
Due Date |
Status |
Notes |
| Fuel system components BOM |
|
|
⬜ Not Started ⬜ In Progress ✅ Complete |
|
| Cooling system components |
|
|
⬜ Not Started ⬜ In Progress ✅ Complete |
|
| Exhaust system |
|
|
⬜ Not Started ⬜ In Progress ✅ Complete |
|
| Miscellaneous hardware |
|
|
⬜ Not Started ⬜ In Progress ✅ Complete |
|
| Cost all materials from catalog |
|
|
⬜ Not Started ⬜ In Progress ✅ Complete |
|
| Cost all manufacturing processes |
|
|
⬜ Not Started ⬜ In Progress ✅ Complete |
|
| Create detailed drawings |
|
|
⬜ Not Started ⬜ In Progress ✅ Complete |
|
11. Fasteners
| Task |
Assigned Member |
Due Date |
Status |
Notes |
| Catalog all bolts and screws |
|
|
⬜ Not Started ⬜ In Progress ✅ Complete |
|
| Catalog all nuts and washers |
|
|
⬜ Not Started ⬜ In Progress ✅ Complete |
|
| Catalog all rivets and pins |
|
|
⬜ Not Started ⬜ In Progress ✅ Complete |
|
| Assign to appropriate systems |
|
|
⬜ Not Started ⬜ In Progress ✅ Complete |
|
| Cost from fastener catalog |
|
|
⬜ Not Started ⬜ In Progress ✅ Complete |
|
12. Materials Costing
| Task |
Assigned Member |
Due Date |
Status |
Notes |
| Steel tubing and sheet metal |
|
|
⬜ Not Started ⬜ In Progress ✅ Complete |
|
| Aluminum materials |
|
|
⬜ Not Started ⬜ In Progress ✅ Complete |
|
| Composite materials (carbon fiber, etc.) |
|
|
⬜ Not Started ⬜ In Progress ✅ Complete |
|
| Plastics and polymers |
|
|
⬜ Not Started ⬜ In Progress ✅ Complete |
|
| Apply Production Volume Factor (PVF) |
|
|
⬜ Not Started ⬜ In Progress ✅ Complete |
|
| Verify all materials in catalog |
|
|
⬜ Not Started ⬜ In Progress ✅ Complete |
|
13. Process Costing
| Task |
Assigned Member |
Due Date |
Status |
Notes |
| Machining operations (lathe, mill, drill) |
|
|
⬜ Not Started ⬜ In Progress ✅ Complete |
|
| Welding and joining processes |
|
|
⬜ Not Started ⬜ In Progress ✅ Complete |
|
| Forming and bending operations |
|
|
⬜ Not Started ⬜ In Progress ✅ Complete |
|
| Heat treatment processes |
|
|
⬜ Not Started ⬜ In Progress ✅ Complete |
|
| Painting and surface finishing |
|
|
⬜ Not Started ⬜ In Progress ✅ Complete |
|
| Assembly operations |
|
|
⬜ Not Started ⬜ In Progress ✅ Complete |
|
| Composite layup and curing |
|
|
⬜ Not Started ⬜ In Progress ✅ Complete |
|
| Task |
Assigned Member |
Due Date |
Status |
Notes |
| Identify parts requiring tooling |
|
|
⬜ Not Started ⬜ In Progress ✅ Complete |
|
| Composite molds and tooling |
|
|
⬜ Not Started ⬜ In Progress ✅ Complete |
|
| Injection molding tools |
|
|
⬜ Not Started ⬜ In Progress ✅ Complete |
|
| PCB manufacturing tooling |
|
|
⬜ Not Started ⬜ In Progress ✅ Complete |
|
| Apply correct PVF (3000 or 150) |
|
|
⬜ Not Started ⬜ In Progress ✅ Complete |
|
| Cost from tooling catalog |
|
|
⬜ Not Started ⬜ In Progress ✅ Complete |
|
15. Documentation & Drawings
| Task |
Assigned Member |
Due Date |
Status |
Notes |
| Create single-page drawings for all parts |
|
|
⬜ Not Started ⬜ In Progress ✅ Complete |
|
| Include dimensions and tolerances |
|
|
⬜ Not Started ⬜ In Progress ✅ Complete |
|
| Show material specifications |
|
|
⬜ Not Started ⬜ In Progress ✅ Complete |
|
| Create assembly drawings |
|
|
⬜ Not Started ⬜ In Progress ✅ Complete |
|
| Exploded views for complex assemblies |
|
|
⬜ Not Started ⬜ In Progress ✅ Complete |
|
| PCB layouts and schematics |
|
|
⬜ Not Started ⬜ In Progress ✅ Complete |
|
| Composite layup schedules |
|
|
⬜ Not Started ⬜ In Progress ✅ Complete |
|
| Wiring diagrams with lengths |
|
|
⬜ Not Started ⬜ In Progress ✅ Complete |
|
16. Add Item Requests (AIR)
| Task |
Assigned Member |
Due Date |
Status |
Notes |
| Identify items not in cost catalog |
|
|
⬜ Not Started ⬜ In Progress ✅ Complete |
|
| Submit AIRs >48 hours before deadline |
|
|
⬜ Not Started ⬜ In Progress ✅ Complete |
|
| Track AIR responses |
|
|
⬜ Not Started ⬜ In Progress ✅ Complete |
|
| Update cost report with approved items |
|
|
⬜ Not Started ⬜ In Progress ✅ Complete |
|
17. Report Quality Control
| Task |
Assigned Member |
Due Date |
Status |
Notes |
| Verify no obsolete catalog items used |
|
|
⬜ Not Started ⬜ In Progress ✅ Complete |
|
| Check all material costs |
|
|
⬜ Not Started ⬜ In Progress ✅ Complete |
|
| Check all process costs |
|
|
⬜ Not Started ⬜ In Progress ✅ Complete |
|
| Verify fastener assignments |
|
|
⬜ Not Started ⬜ In Progress ✅ Complete |
|
| Cross-check drawings with BOM |
|
|
⬜ Not Started ⬜ In Progress ✅ Complete |
|
| Technical review by engineering leads |
|
|
⬜ Not Started ⬜ In Progress ✅ Complete |
|
| Final cost summary verification |
|
|
⬜ Not Started ⬜ In Progress ✅ Complete |
|
18. Cost Scenario Preparation
| Task |
Assigned Member |
Due Date |
Status |
Notes |
| Download scenario prompt from FSAEonline |
|
|
⬜ Not Started ⬜ In Progress ✅ Complete |
|
| Analyze scenario requirements |
|
|
⬜ Not Started ⬜ In Progress ✅ Complete |
|
| Develop engineering solution |
|
|
⬜ Not Started ⬜ In Progress ✅ Complete |
|
| Perform cost analysis for solution |
|
|
⬜ Not Started ⬜ In Progress ✅ Complete |
|
| Create presentation materials |
|
|
⬜ Not Started ⬜ In Progress ✅ Complete |
|
| Prepare one-page summary |
|
|
⬜ Not Started ⬜ In Progress ✅ Complete |
|
| Practice 5-7 minute presentation |
|
|
⬜ Not Started ⬜ In Progress ✅ Complete |
|
19. Report Submission
| Task |
Assigned Member |
Due Date |
Status |
Notes |
| Final report compilation |
|
|
⬜ Not Started ⬜ In Progress ✅ Complete |
|
| Upload to FSAEonline cost module |
|
|
⬜ Not Started ⬜ In Progress ✅ Complete |
|
| Submit 1 day before deadline |
|
|
⬜ Not Started ⬜ In Progress ✅ Complete |
|
| Download PDF copy for records |
|
|
⬜ Not Started ⬜ In Progress ✅ Complete |
|
| Prepare printed copy for competition |
|
|
⬜ Not Started ⬜ In Progress ✅ Complete |
|
20. Cost Addendum Preparation
| Task |
Assigned Member |
Due Date |
Status |
Notes |
| Track changes made after report submission |
|
|
⬜ Not Started ⬜ In Progress ✅ Complete |
|
| Document part modifications |
|
|
⬜ Not Started ⬜ In Progress ✅ Complete |
|
| Calculate cost impact of changes |
|
|
⬜ Not Started ⬜ In Progress ✅ Complete |
|
| Prepare addendum documentation |
|
|
⬜ Not Started ⬜ In Progress ✅ Complete |
|
| Submit at team registration |
|
|
⬜ Not Started ⬜ In Progress ✅ Complete |
|
21. Competition Preparation
| Task |
Assigned Member |
Due Date |
Status |
Notes |
| Assign team members for cost event |
|
|
⬜ Not Started ⬜ In Progress ✅ Complete |
|
| Review cost report thoroughly |
|
|
⬜ Not Started ⬜ In Progress ✅ Complete |
|
| Prepare tools for part removal |
|
|
⬜ Not Started ⬜ In Progress ✅ Complete |
|
| Practice cost scenario presentation |
|
|
⬜ Not Started ⬜ In Progress ✅ Complete |
|
| Prepare supporting materials |
|
|
⬜ Not Started ⬜ In Progress ✅ Complete |
|
| Review competition schedule |
|
|
⬜ Not Started ⬜ In Progress ✅ Complete |
|
Cost Summary Tracking
| System |
Target Cost |
Actual Cost |
Variance |
% of Total |
| Frame & Body |
$_____ |
$_____ |
$_____ |
____% |
| Suspension |
$_____ |
$_____ |
$_____ |
____% |
| Drivetrain |
$_____ |
$_____ |
$_____ |
____% |
| Wheels & Tires |
$_____ |
$_____ |
$_____ |
____% |
| Brakes |
$_____ |
$_____ |
$_____ |
____% |
| Steering |
$_____ |
$_____ |
$_____ |
____% |
| Electronics |
$_____ |
$_____ |
$_____ |
____% |
| Miscellaneous |
$_____ |
$_____ |
$_____ |
____% |
| Fasteners |
$_____ |
$_____ |
$_____ |
____% |
| TOTAL |
$_____ |
$_____ |
$_____ |
100% |
Key Deadlines & Milestones
| Milestone |
Target Date |
Actual Date |
Status |
| BOM organization complete |
|
|
⬜ |
| 50% of parts costed |
|
|
⬜ |
| All AIRs submitted |
|
|
⬜ |
| Drawings 75% complete |
|
|
⬜ |
| First draft complete |
|
|
⬜ |
| Technical review complete |
|
|
⬜ |
| Cost scenario preparation |
|
|
⬜ |
| Final submission |
|
|
⬜ |
Team Member Responsibilities
| Team Member |
Primary Systems |
Secondary Tasks |
Contact |
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Important Resources & Links
- FSAEonline Series Resources: https://www.fsaeonline.com/cdsweb/gen/documentresources.aspx
- Cost Supplement Document: Available on FSAEonline
- Cost Module Guide: Available on FSAEonline
- Online Cost Module: Access through FSAEonline team portal
- Cost Tables/Catalogs: Available on FSAEonline
- Add Item Request Form: FSAEonline Rules Inquiry interface
Weekly Progress Review
| Week |
Review Date |
Progress % |
Issues |
Action Items |
| Week 1 |
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| Week 2 |
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| Week 3 |
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| Week 4 |
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| Week 5 |
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| Week 6 |
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| Week 7 |
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| Week 8 |
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Use this space for important reminders, lessons learned, and additional notes
Last Updated: _______________
Updated By: _______________
