DISCRETE
Uninterruptible Power Supply Systems (200 kVA Three-Phase Online)
Electromechanical assembly: PCB population and reflow, transformer/magnetics winding and lamination, sheet metal fabrication and welding, busbar cutting and plating, subassembly integration, final assembly, Hi-pot and load testing, burn-in, and packing. · US
Total Cost
$27,272 / unit
Capacity (units/year)
10,000
Throughput %
85%
Working capital
$94.0M Mn
Capex
$25.0M Mn
Offsite
$10.0M Mn
Total investment
$129.0M Mn
Lines
15
Net raw material
$9,536
35.0%
Conversion
$17,736
65.0%
Total / unit
$27,272
$ per unit
Raw Material
$9,536 / unit
| Line | Consumption | Unit | Price (USD) | Cost / unit |
|---|---|---|---|---|
| Power electronics module (IGBTs, MOSFETs, capacitors, DC busbars)Live | kg | $54.14 | ||
| Transformer and magnetics (copper windings + electrical steel laminations)Live | kg | $340 | ||
| Control and communication PCBs (bare boards + placed components) | kg | $5,376 | ||
| VRLA battery subsystem (40×12 V 65 Ah sealed lead-acid modules)Live | kg | $3,374 | ||
| Sheet metal and structural enclosures (CR steel, welded and powder-coated)Live | kg | $14.08 | ||
| Cooling fans and aluminum heat sinks (thermal management subsystem)Live | kg | $8.61 | ||
| Wiring harnesses, copper busbars, and connectorsLive | kg | $278 | ||
| Packaging (foam, carton, palletisation) | unit | $90.00 |
Utility
$36.00 / unit
| Line | Consumption | Unit | Price (USD) | Cost / unit |
|---|---|---|---|---|
| Electricity (assembly,ATE,burn-in,environmental control) | kWh | $36.00 |
Operating
$60.00 / unit
| Line | Price (USD) | Cost / unit |
|---|---|---|
| Assembly, testing, and quality assurance labour | $60.00 |
Overhead
$12,500 / unit
| Line | Price (USD) | Cost / unit |
|---|---|---|
| Factory overhead (engineering, facilities, support staff) | $8,500 | |
| SG&A allocation (sales, admin, warranty reserve) | $4,000 |
Depreciation
$250 / unit
| Line | Price (USD) | Cost / unit |
|---|---|---|
| Manufacturing equipment and building depreciation | $250 |
Financing
$4,740 / unit
| Line | Price (USD) | Cost / unit |
|---|---|---|
| Working capital financing (10% WACC applied to 3.5-month cycle) | $4,740 |
Others
$150 / unit
| Line | Price (USD) | Cost / unit |
|---|---|---|
| Quality assurance, first-article testing, and scrap/rework reserve | $150 |
Prices stored in USD; converted to your selected currency at the latest ECB rate. Inputs marked "Live" pull current observed prices from Claight commodity data.