Welding and fabrication
Welding process cost comparison
Compare already-qualified process options using measured production data.
Your inputs
Complete the fields for your selected method. Zero means intentionally zero, not unknown. Currency selection labels amounts; it does not convert exchange rates.
How this calculation works
labor hours*rate+machine hours*rate+consumables+power per option.
Only already-qualified processes. No filler selection, welding procedure approval or structural weld sizing. Machine rate excludes separately entered power and labor.
What information do I need?
Use records for the same job, equipment or accounting period. Only the fields for your selected entry method are required. An unknown amount is not zero.
Input definitions and where to find them
- Qualified process alternatives: One row per distinct qualified process alternatives, on the stated row and period basis. Do not enter both components and their total.
- Measured labor time (person-hours): Measured person-hours for equal accepted output using an already-qualified process.
- Loaded labor rate (selected currency): Matching cost total divided by matching productive/operating hours from invoices, compensation records or logs. Use the field’s exact elapsed/person/machine-hour basis.
- Machine time (hours): Use matching records or a clearly identified owner assumption for machine time, in the displayed unit and the stated row/period scope.
- Machine rate excluding power (selected currency): Machine hourly expense excluding separately entered power/labor.
- Total consumable cost (selected currency): Matching invoice, quote, statement, bookkeeping record or explicit budget amount for total consumable cost. Use the stated period and exclude amounts already counted in another field. Zero means intentionally excluded/not incurred, not unknown.
- Total power cost (selected currency): Measured REAL electrical input for the specified operating state, or clearly labeled compatible rated estimate; no general volts×amps shortcut.
Use the Where to find this value controls beside the inputs for available work-it-out helpers. Estimates remain your assumptions; a helper does not verify the source figures.
Worked example
Example amounts use US dollars (USD).
Example answer: Process 1 total cost is $420.00 for the illustrative inputs below.
Example inputs
- Qualified process alternatives
- Measured labor time: 10.00 person-hours
- Loaded labor rate: $30.00
- Machine time: 5.00 hours
- Machine rate excluding power: $10.00
- Total consumable cost: $50.00
- Total power cost: $20.00
- Measured labor time: 8.00 person-hours
- Loaded labor rate: $30.00
- Machine time: 5.00 hours
- Machine rate excluding power: $10.00
- Total consumable cost: $60.00
- Total power cost: $20.00
- Process 1 total cost
- $420.00
- Process 2 total cost
- $370.00
- Compare equal accepted output; process qualification is supplied externally.
These illustrative values are not recommended rates or industry averages. Replace every example input with your own figures.
Use the result well
Compare already-qualified process options using measured production data.
Keep inputs on the same scope and time basis. Calculations retain precision internally; displayed values generally round to two decimal places, with extra precision for very small values and whole-unit rounding where required. Economic comparisons describe your supplied assumptions and do not guarantee future results.
This tool provides business arithmetic. It does not approve engineering designs, establish legal or tax treatment, select equipment or certify safe operating conditions.