QuoteEstimator - MNMUK Quoting Support

Purpose: Rapid rough-order-of-magnitude estimates for quoting. Not a replacement for proper process planning, but gets you in the ballpark fast.

When to Activate

• "How long to make this part?"
• "Rough quote for [part description]"
• "Estimate cycle time for..."
• "What would it cost to make 500 of these?"
• "Quick estimate for quoting"

Disclaimer

These are rough estimates for quoting purposes. Actual times depend on:

• Specific geometry complexity
• Tolerance requirements
• Surface finish specs
• Fixturing approach
• Tooling availability
• Operator experience

Always add contingency and verify with experienced estimator for critical quotes.

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Machine Hourly Rates

MNMUK Rate Card (Adjust to your actual rates)

| Machine Category | Machine | Rate (£/hr) | Notes | |------------------|---------|-------------|-------| | 5-Axis Mill | NMV3000, DMU50, NHX500 | £85-95 | High capability | | 4-Axis Mill | Vertical VMC | £65-75 | Standard work | | CNC Turning | NLX2500, ALX2000 | £60-70 | Live tooling adds £5 | | Precision Turning | HARDINGE | £75-85 | ±0.003mm work | | Swiss | CITIZEN | £80-90 | High volume, precision | | Wire EDM | MITSUBISHI | £55-65 | Slow but precise | | Spark EDM | MITSUBISHI | £50-60 | Electrode cost separate | | Fast Response | Haas | £45-55 | Prototypes |

Rate Factors

Base Rate × Material Factor × Tolerance Factor × Complexity Factor = Effective Rate

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Material Factors

| Material | Factor | Reasoning | |----------|--------|-----------| | Aluminium (6061) | 0.8 | Fast cutting, easy | | Aluminium (7075) | 0.9 | Slightly harder | | Brass/Bronze | 0.85 | Free machining | | Mild Steel (1018) | 1.0 | Baseline | | Carbon Steel (4140) | 1.1 | Harder, more wear | | Stainless 303 | 1.2 | Free machining SS | | Stainless 304/316 | 1.4 | Work hardening, gummy | | 17-4PH | 1.5 | Tough stainless | | Tool Steel (pre-hard) | 1.3 | Abrasive | | Tool Steel (hardened) | 2.0+ | EDM only typically | | Titanium (CP) | 1.6 | Slow speeds required | | Titanium (6Al-4V) | 1.8 | Very slow, careful | | Inconel 718 | 2.2 | Extreme tool wear | | Hastelloy | 2.5 | Worst case scenario | | Delrin/Acetal | 0.7 | Easy, watch heat | | PEEK | 1.3 | Expensive material | | Nylon | 0.75 | Easy, flexible |

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Tolerance Factors

| Tolerance Band | Factor | Notes | |----------------|--------|-------| | ±0.25mm (±0.010") | 0.9 | Loose, fast | | ±0.125mm (±0.005") | 1.0 | Standard | | ±0.05mm (±0.002") | 1.2 | Careful work | | ±0.025mm (±0.001") | 1.4 | Precision | | ±0.012mm (±0.0005") | 1.7 | High precision | | ±0.005mm (±0.0002") | 2.0 | Grinding territory | | ±0.003mm | 2.5 | Swiss/HARDINGE only |

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Complexity Factors

| Complexity | Factor | Examples | |------------|--------|----------| | Simple | 0.8 | Round part, few features | | Standard | 1.0 | Typical machined part | | Moderate | 1.3 | Multiple setups, tight tolerances mixed with loose | | Complex | 1.6 | 5-axis, multiple operations, thin walls | | Very Complex | 2.0+ | Extreme geometry, exotic material + tight tolerance |

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Cycle Time Estimation

Turning Operations

OD Turning

Time (min) = (Length × Passes × π × Diameter) / (Feed × Speed × 1000)

Simplified:
Rough: Volume removed (cm³) × 0.5 min/cm³
Finish: Surface area (cm²) × 0.02 min/cm²

Quick Estimates - OD Turning:

| Part Size | Rough | Finish | Total | |-----------|-------|--------|-------| | Ø25 × 50mm | 0.5 min | 0.3 min | 0.8 min | | Ø50 × 100mm | 2 min | 1 min | 3 min | | Ø100 × 150mm | 6 min | 2.5 min | 8.5 min | | Ø150 × 200mm | 12 min | 4 min | 16 min |

ID Boring

Multiply OD time × 1.5 (slower, less rigid)
Deep bores (L/D > 4): × 2.0

Threading

Single-point: 0.3 min per 25mm thread length (standard pitch)
Thread milling: 0.5 min per thread
Tapping: 0.1 min per hole (standard)

Grooving/Parting

Grooving: 0.2 min per groove
Part-off: Diameter (mm) × 0.01 min

Milling Operations

Face Milling

Time = (Area / (Width of Cut × Feed Rate)) + Approach

Quick: Area (cm²) × 0.02 min/cm² for roughing
       Area (cm²) × 0.01 min/cm² for finishing

Pocket Milling

Volume (cm³) × 0.8 min/cm³ (aluminium)
Volume (cm³) × 1.5 min/cm³ (steel)
Volume (cm³) × 3.0 min/cm³ (stainless/titanium)

Add 50% for finishing passes

Drilling

Standard drill: Depth (mm) × 0.02 min/mm
Peck drilling: Depth (mm) × 0.04 min/mm
Deep hole (>5xD): Depth (mm) × 0.08 min/mm

5-Axis Contouring

Surface area (cm²) × 0.15 min/cm² (aluminium)
Surface area (cm²) × 0.3 min/cm² (steel)
Surface area (cm²) × 0.5 min/cm² (titanium)

Complex surfaces: Add 50-100%

Swiss Operations

Small precision parts (Ø3-10mm):
- Simple: 30-60 sec/part
- Standard: 60-120 sec/part
- Complex: 120-300 sec/part

Medium parts (Ø10-25mm):
- Simple: 60-120 sec/part
- Standard: 120-240 sec/part
- Complex: 240-480 sec/part

EDM Operations

Wire EDM

Cut length (mm) × thickness (mm) × 0.003 min/mm² (roughing)
Add 50% per skim pass (typically 2-4 skim passes)

Example: 100mm perimeter × 25mm thick
- Rough: 100 × 25 × 0.003 = 7.5 min
- 3 skims: 7.5 × 1.5 × 1.5 × 1.5 = 25 min total

Spark EDM

Volume to remove (cm³) × 30-60 min/cm³
Roughing faster, finishing much slower
Electrode making: Add 1-4 hours depending on complexity

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Setup Time Estimates

| Operation Type | First Setup | Repeat Setup | |----------------|-------------|--------------| | Simple turning | 30 min | 15 min | | Complex turning (live tooling) | 60 min | 30 min | | Swiss | 90 min | 45 min | | 3-axis milling | 30 min | 15 min | | 4-axis milling | 45 min | 20 min | | 5-axis milling | 60-90 min | 30 min | | Wire EDM | 30 min | 15 min | | Spark EDM | 60 min + electrode | 30 min | | Multiple operations | Sum of each | Sum × 0.7 |

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Quick Quote Formula

Total Cost = (Setup Cost) + (Run Cost × Quantity) + (Material Cost) + (Secondary Ops)

Where:
- Setup Cost = Setup Time × Hourly Rate
- Run Cost = Cycle Time × Hourly Rate × Material Factor × Tolerance Factor
- Material Cost = Weight × £/kg × Waste Factor (typically 1.3-1.5)
- Secondary Ops = Finishing, heat treat, plating, inspection (get quotes)

Quantity Breaks

| Quantity | Multiplier | Notes | |----------|------------|-------| | 1-5 | 1.5 | Prototype pricing | | 6-25 | 1.2 | Small batch | | 26-100 | 1.0 | Standard | | 101-500 | 0.9 | Efficiency gains | | 500+ | 0.8 | Volume pricing |

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Estimation Workflow

Step 1: Feasibility (Use PlantCapability)

• Can we make it?
• Which machine?
• Any showstoppers?

Step 2: Operation Breakdown

| Op# | Description | Machine | Setup | Cycle |
|-----|-------------|---------|-------|-------|
| 10 | | | min | min |
| 20 | | | min | min |
| 30 | | | min | min |

Step 3: Apply Factors

Base cycle time: X min
× Material factor (Y): X × Y = Z min
× Tolerance factor (T): Z × T = A min
× Complexity factor (C): A × C = B min
Adjusted cycle time: B min

Step 4: Calculate Costs

Setup: [time] × £[rate] = £____
Run: [cycle] × [qty] × £[rate/60] = £____
Material: [weight] × £[per kg] × 1.3 = £____
Secondary: £____
Subtotal: £____
Margin (25-40%): £____
**Quote: £____**

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Quote Output Template

# ROUGH QUOTE ESTIMATE

**Date:** YYYY-MM-DD
**Customer:**
**Part:**
**Quantity:**

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## Part Summary
- Material:
- Envelope: L × W × H mm
- Weight (est): kg
- Key tolerances:
- Surface finish:

## Feasibility
- [x] Within capability
- Machine(s):
- Risks:

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## Operations Breakdown

| Op | Description | Machine | Setup (min) | Cycle (min) |
|----|-------------|---------|-------------|-------------|
| 10 | | | | |
| 20 | | | | |
| 30 | | | | |
| **Total** | | | **X** | **Y** |

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## Factors Applied

| Factor | Value | Reasoning |
|--------|-------|-----------|
| Material | × | |
| Tolerance | × | |
| Complexity | × | |
| **Combined** | **×** | |

**Adjusted cycle:** Y × [combined] = Z min/part

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## Cost Calculation

| Item | Calculation | Cost |
|------|-------------|------|
| Setup | X min × £[rate]/60 | £ |
| Run (× qty) | Z min × [qty] × £[rate]/60 | £ |
| Material | [wt] × £[/kg] × [qty] × 1.3 | £ |
| Secondary ops | [detail] | £ |
| **Subtotal** | | **£** |
| Margin ([%]) | | £ |
| **Quote Total** | | **£** |

**Per Part:** £ each at qty [X]

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## Assumptions & Exclusions

### Assumptions
-

### Exclusions
-

### Validity
- Quote valid for: 30 days
- Lead time estimate: X weeks

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## Notes

### Risks
-

### Alternatives
-

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*Rough estimate only. Final quote subject to drawing review and process planning.*

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Quick Reference Tables

Cycle Time Rules of Thumb

| Part Type | Quick Estimate | |-----------|----------------| | Simple turned (Ø25-50) | 2-5 min | | Complex turned (Ø50-100) | 8-20 min | | Swiss part (small) | 1-3 min | | Simple prismatic (milled) | 5-15 min | | 5-axis component | 20-60 min | | Wire EDM profile | 30-120 min |

Setup Time Rules of Thumb

| Scenario | Estimate | |----------|----------| | Repeat job, tooling available | 15-30 min | | New job, simple | 30-45 min | | New job, complex | 60-120 min | | New job, 5-axis or Swiss | 90-180 min |

Cost Sanity Checks

| Part Type | £/part Range (qty 100) | |-----------|------------------------| | Simple turned bushing | £2-8 | | Complex turned shaft | £15-50 | | Swiss precision pin | £3-15 | | Milled bracket (aluminium) | £10-40 | | 5-axis aerospace part | £50-500 | | EDM detail | £30-200 |

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Example Estimates

Example 1: Turned Shaft

Part: Ø50 × 150mm shaft, 4140 steel, ±0.025mm on bearing diameters Qty: 100

Operations:
- OP10: Face, turn OD, drill center (NLX2500)
- OP20: Flip, face to length, finish bearing seats

Cycle estimate:
- Rough turning: 4 min
- Finish turning: 2 min
- Total: 6 min base

Factors:
- Material (4140): × 1.1
- Tolerance (±0.025): × 1.4
- Complexity (standard): × 1.0
- Combined: × 1.54

Adjusted cycle: 6 × 1.54 = 9.2 min

Costs (at £65/hr):
- Setup: 45 min × £65/60 = £49
- Run: 9.2 min × 100 × £65/60 = £997
- Material: 2.3kg × £3/kg × 100 × 1.3 = £897
- Subtotal: £1,943
- Margin (30%): £583
- Quote: £2,526 (£25.26/part)

Example 2: Swiss Medical Pin

Part: Ø4 × 20mm pin, 316SS, ±0.01mm, qty 1000 Machine: CITIZEN LFV

Cycle estimate: 90 sec base (complex small part)

Factors:
- Material (316SS): × 1.4
- Tolerance (±0.01): × 1.5
- Complexity (moderate): × 1.3
- Combined: × 2.73

Adjusted cycle: 90 × 2.73 = 246 sec = 4.1 min

Costs (at £85/hr):
- Setup: 90 min × £85/60 = £128
- Run: 4.1 min × 1000 × £85/60 = £5,808
- Material: 0.02kg × £8/kg × 1000 × 1.3 = £208
- Subtotal: £6,144
- Margin (30%): £1,843
- Quote: £7,987 (£7.99/part)

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Integration

• PlantCapability: Check feasibility before estimating
• CNCSetup: Setup times based on actual setup sheet complexity
• TribalKnowledge: Adjust factors based on captured experience
• AutomotiveManufacturing: Link to PPAP/APQP costing requirements