Quoteestimator

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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Examples

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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Workflow Routing

Trigger	Action
"quote", "estimate", "pricing", "how much to make"	Run full estimation workflow (Steps 1-4)
"cycle time", "how long to make"	Run cycle time estimation only (Steps 1-3)
"rough quote", "ballpark", "sanity check"	Use quick reference tables for rapid ROM estimate
"feasibility", "can we make"	Defer to PlantCapability skill first
"cost per part at qty X"	Apply quantity break multipliers to base cost

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