# FSAE Cost Report Preparation Checklist ## Team Information - **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 | | --- ## 14. Tooling Costs | 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 | |-------------|----------------|-----------------|---------| | | | | | | | | | | | | | | | | | | | | | | | | | --- ## 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 | | | | | | Week 2 | | | | | | Week 3 | | | | | | Week 4 | | | | | | Week 5 | | | | | | Week 6 | | | | | | Week 7 | | | | | | Week 8 | | | | | --- ## Notes & Comments _Use this space for important reminders, lessons learned, and additional notes_ --- **Last Updated:** _______________ **Updated By:** _______________