Cost and Manufacturing Update - March 2022

Head Cost & Manufacturing Judge John Dangerfield provides an update to all FS and Concept Class teams competing in the summer competition.

Hi Teams, a couple of key points I would like to update on for the Cost and Manufacturing Event for all teams taking part at Silverstone in July 2022.

Documents Required

This year we need FS Class (Class 1) and Concept Class (Class 2) to both upload the CRD (Cost Report Documents) to the portal by the deadline.

FS Class

1. CBOM – Frame and Body & Powertrain, DBOM – All other areas
2. Cost Explanation File
3. Cost Supporting Documents

Concept Class teams:

1. CBOM – Frame and Body only, DBOM – Frame and Body Only
2. Cost Explanation File
3. Cost Supporting Documents
4. Presentation of the Special Task

Please supply these in PDF format, A4 portrait only and remember to bring hard copies to the event too.

Deadlines - really important

There will be zero mitigation for late submissions. Actually zero.

For any reason.

If your system fails or our website isn’t available; zero, nothing.

1 second over is late.

You should assume that the portal will crash on the submission day and submit early. If this happens it will be your fault for not taking notice of this warning not ours.

I will help you and guarantee your completed submission if you flag issues to me via the FSQD up to the 3 June 2022. Please, please don’t leave it to the last minute.

If you do miss the deadline penalties will apply, there will be no appeal, but I will be happy to explain why we take this strict stance on the day at the event to anybody who wants to know.

Using the Cost Tool

In one of our videos, we indicated that we were trying to change up the Cost Tool to make it more EV friendly. This is still an objective, and we will aim to gather more info in this this year to try and implement for next year.

In the meantime, in the Powertrain section, we have added an “other” field to the drop down to try and assist EV teams to be able to locate their correct components in the correct location. Hopefully this will be a useful addition for this year. That update is live now along with a number of other bug fixes too.

Concept Class – Special Task

In addition to the new Concept Class Cost Final, we will also be asking the teams to undertake a presentation on the topic below. Delivery of the presentation is down to you.

No equipment will be provided so you will have to be innovative in your delivery. You will be left to present the solution to the task and questions will come at the end of the presentation.

The duration should be no longer that 10-15 minutes and that time frame should allow for Q&A too.

Your Special task for 2022 is:

Your Formula Student Team have been approached by a new single seat racing league that is setting up a global competition in multiple countries, they have seen your prospective frame and body design and really interested in taking on your proposed design for use in their global series.

They would like you to present how you would scale up your manufacturing setup from the current single one-off product to produce 10,000 units over the next 5 years. With a ramp up of 100 units in year 1, followed by 2475 units for the remaining 4 years.

Things you may wish to consider (there maybe others)

• Materials used
• Manufacturing processes & feasibility
• Assembly processes
• Tooling
• Capital investments

Hopefully this gives you all the information you need at this stage. I wish you the best of luck for Formula Student this year and can’t wait to meet you all properly at Silverstone.

Best Regards,
Head Cost and Manufacturing Judge,
Formula Student