Prototype factories (rapid prototyping/sampling factories) often face the dilemma of “constant orders and meager profits”, with the core being that a large amount of hidden costs are concealed by traditional accounting methods. Here are the main ‘hidden bills’:
1、 Process and quality loss costs
About 60% of manufacturing companies incur additional costs due to process issues, resulting in an average increase of 15% in overall manufacturing costs. Specifically manifested as:
The substandard flatness of the material triggers a chain reaction: laser cutting deviation, welding misalignment, and assembly difficulties
Rework or even scrap, these costs are often evenly spread across all orders and difficult to trace
2、 Hidden expenses in CNC machining
The hidden costs of traditional CNC prototype models are often underestimated:
• Tool wear and tear: accounting for 15% -25% of material costs
Trial and error rejection rate: The first success rate is less than 70%
Post processing labor: accounts for 30% of the overall cost
Small batch trial production makes it difficult to allocate mold costs, resulting in high individual costs
3、 Out of control labor costs
The scarcity of skilled workers has led to vicious competition in wages, with wages increasing from 3000 yuan to 10000 yuan
The piece rate wage statistics are lagging behind and cannot truly reflect the actual costs of each process
The processing fee has been reduced from tens of yuan to a few yuan, and the profit margin has been squeezed to the point of being exhausted
Breaking direction
1. Introduction of 3D printing technology: Complete complex prototypes within 24 hours, support on-demand manufacturing, and reduce small and medium-sized batch costs by 40% -75% compared to traditional processes
2. Digital management: Realize full process cost transparency through ERP system, accurately calculate each process
The profit of the prototype factory is as thin as paper, and its essence is that extensive management cannot penetrate the cost fog. Only by making hidden costs explicit can we transform from “order taking machines” to “value creators”.
