| Making a part seems to be simple mathematics; a chunk of brass that cost a few bucks is turned by a fancy machine that only takes a few minutes to make the shape, which adds a couple more dollars, right? So why charge so much?
Take a look at unseen and less than obvious things it takes to produce a finished MP out of a cheap piece of brass:
A Laser Scanner for Reverse Engineering and training for the operator of the Scanner plus the increased value of the employee who has such a skill (increased wages) the cost of the machine unknown
The Scanned program is then imported into CAD/CAM (Computer Aided Design & Machine program) so that it can be translated into machine language (G-Code or M-Code for the Mazak) The CAD operator and CAM operator need extensive training, not to mention the computers and office space to do the work, including telephones, internet services and even someone to clean the bathrooms. $250,000 for a Mazak Turning Center with computer controls is reasonable.
Take into account, there are trials parts to make sure the product is like the original..... called prototyping. Changing the program may take several times between engineering, programming and the machinist to get a first article.... a part good enough to put into production.
Prep time for the MP, which includes ordering raw stock, saw cutting the pieces for handling in the lathe (someone has to do all this stuff including purchasing agents, secretaries (she pays the bills later on) and the saw shop guy handling the raw stock..... all time that you can't see in the part.
Don't forget the tooling cost. Each part may use several types of cutting bits, tooling and special tapered drills just to make one part. Carbide bits, special order tooling and high speed drills cost a lot of money.
Now who's paying for the lathes electricity, the coolant in the lathe (which keeps the part from warping) and cleaning the lathes after a full day of production... can't have a $30/hour machinist doing this.... hmmm someone else employed maybe?
For the machinist, he has to know set-ups (each part has different set ups and programs) and the proper tooling for each job. Once the part is turning, to be of any value, he'll watch the tolerances, the speeds and feeds of the spindle, which can make or break whether parts come out within tolerance. It takes time to complete one side then rotate the part and hold it on the other end, in machine lingo, it's a second op (or second operation) You simply can't make the part in just one pass from one direction, essentially the chuck (the holder) is in the way for the tool (cutter) to complete the part. So it must be rotated..... time, plain and simple... the more time, the more cost to the manufacturer.
Ahhh, then the magic word, tolerances, a part with tight tolerances +/-.001 (that’s 3 times thinner than the average human hair) takes longer to produce. Time again. I don't know how MP are manufactured but I'm sure some final finish is added... buffed or semi-polished before sent to plating?
Once out of the machine, the part is then deburred. (The sharp edges that the lathe has left have to be removed)
More prep time for the plating, which includes the acid dip and hanging the parts. It’s not just someone throwing parts into a vat of silver. Once finished, they are stamped, polished and packaged. Packing those little things doesn’t come free, it cost the manufacturer. Shipping depends on who pays for that too.
Other unforeseen cost; let’s say someone is looking for a MP, he emails a question, someone must take the time to write back. Let’s say you call and have several questions, the secretary is involved, then the person answering the technical questions…. both those people involved are costing the company an hourly wage.
For simplicity, let’s say there were only 10 people total involved in making a MP and they made an average of $20/hour ($10/hour for low end employees and $30/hour for top end) each person makes $5.00/hour in benefits from the company. i.e. insurance, vacation time, holiday pay and etc…. (that’s cheap, especially for California) This is the labor portion of making the MP, not the manufacturing cost of doing business. (I have mentioned some of them above)
As you can see, the price of a “cheap” piece of brass can add up quickly….. thus the quandary for the seller between price and what the consumer will pay for the product. They HAVE to make a profit to stay in business but can't gouge the customer either or there will be no business after a while. It's a balance for the business, who carries all the risk of buying and maintaining equipment. As well as, keeping his people busy and happily employed.
$135 for a MP that has hours of time invested per part seems reasonable to me.
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53' Olds Ambassador |