How to Transition from Low Volume to Production - Efficient Short Run Strategies

Businesses need to move from low production to full-scale production. This helps them meet the growing needs of the market.

Additive manufacturing is good for low production. It offers design flexibility and allows for quick prototyping.

Smart short-run methods, such as automation and batch production, make things simpler and lower costs.

To grow well, you need to understand economies of scale. You must also manage costs and control inventory.

Working with a trusted manufacturer like REV A MFG can help you face the challenges of raising production.

In today's fast-paced business world, companies strive to make their product creation better. Switching from small-scale production to larger production requires detailed planning. This blog post discusses effective methods to manage short-run production. It emphasizes the need for efficiency, cost savings, and process improvements to ensure steady growth and stay ahead of others.

In today’s fast-changing manufacturing world, it is important to have good short-run strategies. These strategies can help you get to market faster and thus stay ahead of your competitors. If you are starting a new product or if you run an established company in a small market, making your product out faster can really increase your market share.

You can use lean manufacturing methods. These ways can improve production steps. You can also use automation. These actions help businesses be more flexible. They can reduce wait times. This way, businesses can meet customer needs quickly like never before.

Moving from Prototype to Low Volume Manufacturing

Moving from a prototype to producing smaller amounts of products needs careful planning and action. This change needs a smooth transition from the first design to creating a few parts. Manufacturers often face challenges when they try to move from one prototype to several products. Using smart methods like plastic injection molding or selective laser sintering can make this shift easier. If small businesses start using these effective techniques early, they can benefit a lot. It helps them bring their creative designs to market quicker and improve their process.

How to Leverage Additive Manufacturing / 3D Printing for Low Volume Production

Additive manufacturing is a low-cost method to create small quantities of products. It helps businesses enhance their production lines using methods like Multi Jet Fusion (MJF) and Selective Laser Sintering (SLS). These techniques allow for making complex designs with special mechanical features to meet different industry needs. By using the unique perks of additive manufacturing, small businesses can stand out, cut down on wait times, and improve their ability to change production as needed.

Is the Cast Urethane Process an option to consider?

For small businesses that want to move from prototypes to a pilot run, the cast urethane process is a potentially a great choice. This method allows for parts with complex designs to be made at a good price, using a 3D printed part as a mold. Making between 20 and 100 parts usually works best for cost savings. This process uses silicone tooling in conjunction with thermoset urethane plastic materials for your parts. These materials can look and function very similar to real production thermoformed plastics.

The quick turnaround and dependent upon the design, low cost for tooling make Silicone Tooling with cast urethane parts a potentially great option for businesses ready to launch a new product with a quality pilot run.

Class 103 injection tooling offers high-quality production at a lower cost compared to Class 101 and 102 tooling. It provides a good mix of precision and affordability. This makes it ideal for small-run manufacturing. Small businesses or startups can save on initial costs while still making quality parts. With Class 103 injection tooling, you can create cost-effective production tooling and utilize production thermoplastics.

In today's changing manufacturing world, short-run strategies to understand your options is crucial. Ultimately they can help you get your product into customers hands faster. Whether you are a new business launching a product or a well-known company targeting a small market, your access to short run technologies can be a gamechanger.

Economies of scale in production can lower costs as production increases. When businesses produce more items, the cost for each item often decreases. This is because they can make better use of their resources and improve how they make things. With lower costs, companies can share fixed costs over more products, making more profit for each one. Plus, when companies take advantage of economies of scale, they can invest in better technology, improve the quality of their products, and make their processes work better. By focusing on scalability, they can provide better prices, boost their profit margins, and improve overall efficiency.

Transitioning from low-volume to full-scale production needs a smart plan. The focus should be on optimizing production time, reducing lead times, and using the benefits of Lean manufacturing with larger scale production. You will need to work with your supplier, look at their production capacity at the time within that strategy in order to make the push move along smoothly.

In manufacturing operations, deciding between batch production and continuous flow is important for being efficient. Batch production makes a specific number of parts in a set time. It offers some flexibility, but if not managed well with your supplier, can lead to issues between your customers demand and your lean inventory.

Continuous flow, however, keeps a steady process with little pause between each unit. This is better for producing larger inventory of parts for steady customer demand. By understanding the differences between these two methods, you can help make your production processes better with your supply chain, which in turn can help improve costs and productivity.

Changing how much a business produces, from low to high levels, needs careful planning up front. When defining a production routine, even small cost changes can build up and impact profits. Businesses must carefully examine every step of their production with their supplier. They should look for ways to lower costs and improve what they do while keeping the quality strong.

This could mean speaking with suppliers to get better prices when buying in large amounts.

It might also involve using lean manufacturing to waste less.

Looking at automated processes can help lower labor costs.

Good cost management and careful budgeting are important for a smooth and successful move to large-scale production.

Budgeting for In-House Production: What to Anticipate

If you already have manufacturing capabilities within the organization, have you considered bringing the tool making and Injection Molding as things that can be brought within your scope of work? Budgeting for a potential insourcing of your production might be something to consider.

Here is quick exercise just for you to consider what this process could entail.

Looking closely at these categories, particularly in finding the right human capital to run the operation can be worth effort in analyzing. By planning ahead, you can potentially lower your costs in the long term and support your products’ growth within your organization directly. An exercise worth the effort but the vast majority of companies choose to outsource their Injection Tooling & Molding requirements.

For a deeper dive, have a look at this informative 

Inventory Management for High Volume Protection

Effective inventory management is important for high production levels. Using modern tools and data systems can simplify the process. This reduces waste and increases efficiency. Utilizing a good 3PL provider can offer you access to these strategies.

With good inventory tracking software and smart methods in place, businesses can maintain a "Goldilocks" amount of product in stock. Having access to this Real-time data can reveal trends in demand, which helps businesses decide on manufacturing strategy, quickly.

Paying attention to accurate forecasting and organizing the warehouse is crucial for good inventory management in high production. A proper balance between supply and demand is the key to success.


Simplify the Transition from Prototype to Production with REV A MFG

We know your prototype means a lot; it shows your vision. Our team will work closely with you in developing a design that works as your team intends it to while also being highly manufacturable. We will give you the proper feedback within a custom and efficient Design for Manufacturing (DFM) Report and use our experience to make sure your design is ready for launch. By choosing REV A MFG, you make it easier to go from prototype to production which will help you launch your product faster and smoother.

Navigating the product life cycle can sometimes be tough. It starts with a prototype and then moves into some type of production cycle. REV A MFG is here to help you as a trusted manufacturing partner. Between all of our team members, we have many years of experience and know the challenges you may encounter. REV A MFG offers complete solutions to support you at each stage of your product's journey.

Efficient short-term plans are crucial for boosting production. You can improve manufacturing by using automation, picking the right materials, managing costs, and budgeting well. These steps help you save money and increase production efficiency. In working with the team at REV A MFG, we can add value to your project by helping you have a view at all of your potential short-run options. Not only do we have the experience in the world of Additive Manufacturing processes and materials, we can also offer you options in where to start with your production manufacturing needs including CNC Machining, bent sheet metal and a host of options with tooling and molding thermoplastics.

 to begin your discussion on short-run strategies today!

What are the first steps in transitioning from low volume to production?

Start by doing a complete market study to understand the demand for your product. Get your first prototypes made and utilize this CAD model to begin exploring your options with tooling for short run manufacturing as well as larger production runs. After your choices have been made it's important to do a pilot run, focusing on quality control, before moving on to full production.

What Additive technology is a good fit for Production?

Selective Laser Sintering (SLS) is a commonly employed technique recognized for producing robust components with excellent material properties, making it effective across various industrial applications over the 15 years. The MJF - Multi Jet Fusion had made a big impact in the last 5 years with many companies utilizing the better aesthetics and lower cost of builds to their advantage, using MJF for serial production additive manufacturing. The design freedom allowed, particularly early in a designs life is another benefit of AM.

How can small businesses efficiently manage the transition to high volume production?

Small businesses should look to adopt strategies that allow them to scale up and find cost-effective solutions within that strategy. Spending the time to understand your different options with your Production Manufacturing resource allows you to walk into a project, eyes wide open with the knowledge of where you are starting and what options are available as you scale up.

Reach out to go over your low and high volume options with REV A MFG today! 

Efficiently transition from low volume to production with short run manufacturing strategies. Explore more on our blog!

Short Run Manufacturing Strategies

CNC Machining: 3 Easy Tips to Reduce Lead Time

Look into important factors like choosing the right materials, machine, vendor and the readiness of your program.

Tips to find ways for your CNC machining Quote and Order processes to work better and more efficiently.

Review multiple factors for you to consider when putting together a CNC RFQ package and process for best results.

Have an Important Project on Deck? These are some Key Factors for Consideration that can Influence CNC Machining Lead Times

Getting quality CNC machined parts in your hands quickly is something we do every day for our customers at REV A MFG. While the overall part size and geometry of your part can be big factors for CNC machining lead times, being aware of what other factors can be influential in subtractive manufacturing process can help the timeliness of getting finished parts back to you as fast as possible.

3 Easy Tips & Tricks for Reducing CNC Lead Times

For a project to move quickly from start to finish, designers, machinists, and project managers need to understand the best ways to work together. By being aware of efficiencies, you can reduce the time it takes to get parts in hand and this can be all be done without losing quality or precision.

Whether you are getting your parts cut down the street, or using a shop with local capabilities and global reach when you need it like REV A MFG, clear communication is the best way. Doing your best to effectively communicate your design is the how.

Effective Manufacturing Drawings for Production Manufacturing

When your expectations are high for the end results, the work put in communicating your part geometry and design intent goes a long way. How you articulate your part requirements is paramount. Ensure that your part and assembly drawings are thoroughly and correctly dimensioned, toleranced, annotated and with any details that need explaining are provided when it comes to complex geometries and their engineered intent.

Thorough RFQ Packages in help for Reducing Leadtime CNC

While creating a great RFQ package can sometimes be tedious, it is a critical part in setting the stage for your vendor and the time it takes should be considered by you and your team as time well spent. Having a standardized approach across all of your work offers a chance for your vendors to understand your particular style of communication and makes it easier for you to operate as your body of work increases through your career. We know you are a badass, your RFQ packages can really help you shine.

Tip #2 - Optimized Supplier Communication

Communication problems and misunderstandings often cause delays and mistakes in projects. Clear communication is key to achieving successful results within your supply chain.

Creating good relationships with CNC machining partners and keeping open communication during the entire project helps finish on time, reduce mistakes, and makes the manufacturing process smoother and more efficient.

Effective Communication & Collaboration with your Vendor

Effective teamwork begins with checking the design details together. This helps everyone involved know the design goals and how it can be produced. Using online review tools to share designs, get feedback, and watch progress in real-time with a Project Manager at REV A MFG can be hugely beneficial. Our PM team has years of manufacturing experience, many of them having come from the shop floor themselves.

Video calls are a great option to help everyone quickly get on the same page with design, material choices, and any potential manufacturing issues. This approach can reduce misunderstandings and cuts down on potential Engineering Change Orders later. Our knowledge of manufacturability can offer important ideas that stop costly delays due to design changes. This is very important for custom parts that have tight tolerances or unique shapes. Close teamwork will lead to better results.

Effective project management is very important for finishing CNC machining projects on time. We prefer to take a collaborative approach to managing projects from the outset in defining your priorities for the project. Managing our collective expectations and these factors well can absolutely help shorten lead times. There are many things we are considering when reviewing your projects. Here are a few insights for your consideration so that we can take the collaborative approach and discuss our options:

 - Plays a big role in overall lead times in CNC machining. This includes the time needed to secure the workpiece, load the program, adjust the tools, and do test runs. To make setup times shorter, we need better processes and skilled operators. Improving setups by using standard fixturing systems, offline programming, and planned downtime for maintenance of equipment. This ensures production runs smoothly and helps speed up the delivery of production parts.

 - As you know, a key part of a successful program involves choosing the right material for your application. This choice will affect the cost and lead time of a project. It is important to consider options like wear resistance and tensile strength to to ensure peak performance from your parts. Some materials may have unique setup requirements. These requirements can impact cutting speeds and possibly how quickly tools can wear out. For example, aluminum is easy to work with and allows you cut faster than harder metals like stainless steel. Choosing materials that are easy to procure can speed up production. If you need special or hard-to-find materials, there could be some sourcing delays. Another reason to work closely with your CNC machining partner: we can help you understand material lead times and suggest other options if needed.

 - Multiple setups, undercuts and milling time are all factors that we review when quoting your designs. The quality of your CAD file as well as design manufacturability are also important considerations at this point.

 - Timely access to the right CNC machine is very important for meeting your project deadlines. When machines are available, it can help reduce lead times and us talking about your requirements in advance for a wide range of applications which can help with machine planning. Finding a CNC machining partner that has many machines and plenty of capacity can help prevent delays, especially for complex parts that need multi-axis machining.

With all of these discussion points in mind, keeping an open line of communication with manufacturing partners builds a mutual trust and can help address any unexpected challenges quickly. By creating a teamwork-focused environment, issues can be solved early, reducing delays and boosting the chances of project success.

We are well versed in helping companies launch successful CNC programs for both Prototype and Production needs. Our machining capabilities can be leveraged to assist in bringing your program to life. Please 

 or reach out to us with a phone call in advance of your program being ready to 

Want to really dive deep into the topic of Supplier Quality? Check out this great article from 

How can design complexity impact CNC machining lead times?

In product development, the overall size, shape and design of parts can greatly impact how long the CNC machining production process takes. Complex designs often need more detailed machining processes, materials with unique properties and timing. They may also require special tools but these can be identified at the early stage of a program during the RFQ process. All these factors can potentially raise the production time for CNC parts.

Looking to reduce lead times in CNC machining? Discover effective strategies for optimizing your manufacturing processes.

Lead Time Reduction Strategies for CNC Machining

This blog shares a complete checklist that covers quality, cost, delivery, rules, and more.

You will learn how to make your evaluations better, use technology smartly, and build strong supplier relationships.

Find out common mistakes to skip, so you can choose the best suppliers for your needs.

Get the tools for you and your procurement teams to improve your buying process and support lasting business growth.

Are you on the hunt for a good Production Manufacturing resource? Have you ever found that searching for the right supplier for a Production source for CNC Machining, Injection Tooling and Molding or Additive Manufacturing has been difficult? It really doesn’t need to be.

Doing proper evaluations for current manufacturing suppliers is key for great supplier relationship management. In this post, we will discuss how smart teams can choose better suppliers, create strong partnerships, and keep supply chains running smoothly. Are you ready to honestly assess your supply chain? We believe that 

 could be a great resource for you, and we will provide a clear and objective summary for you to consider us and others by within this exercise.


Understanding Supplier Evaluation: A Fundamental Overview


Supplier evaluation is important for making sure the companies you work with are great. It involves checking their 

 by assessing their quality, delivery, and how well the company fits your specific needs.

Typically Lead Time, Price and Quality are your three main considerations in any given opportunity but vetting your suppliers in advance of a specific opportunity is always a great exercise to run through. You should think of supplier evaluation like checking references before hiring someone. You wouldn't pick a supplier without looking into their background. By doing regular evaluations, you allow for 

. This helps you prevent any potential future issues, build strong manufacturing partnerships, and keep your purchasing prowess and skills sharp.

 
The Role of Manufacturing Supplier Evaluation in Business Success

 
Now, you may be asking, "How does supplier evaluation affect my profits?" The answer is straightforward. A strong 

When you pay close attention to your suppliers, you can better manage risks in your 

. Consider the impact of late deliveries, poor quality, or your chosen supplier having their own supply chain problems can really disrupt your operations.

The good news is that regular supplier evaluations alert you to problems early. They serve as an early warning system, helping you find possible issues before they turn into big troubles.


Differentiating Between Price and Value in Supplier Selection

We pretty much all love a good deal, right? But when choosing a supplier in the past, you have likely had the experience where your cheapest alternative has not always turned out to be the best choice. Of course it’s easy to focus only on price, but ignoring the hidden costs can absolutely bring you real problems down the line in your contract management.

To make informed choices, we must look beyond just the numbers. Yes, cost is a very important factor, but looking at other factors, like trustworthiness, how the vendor communicates, and their promise to ethical sourcing very much matters. Considering these other factors objectively as a part of your score within evaluations can help to show you the real value they can provide.

Crafting Your Supplier Evaluation Checklist


Ready to roll up your sleeves and create your very own 

supplier performance evaluation checklist

? It's easier than you think! A handy tool you can utilize is a 

. This allows you to score potential partners on the criteria that matter most to your business.


Here's a simple framework to get you started:


Identifying Critical Performance Indicators


Now that you have your scorecard ready, it’s time to choose your VIPs – your most important key performance indicators (KPIs). What is THE most important thing and the key considerations overall for your team to be looking at in this project? These are the key metrics that help you measure a supplier's success.


To find your KPIs, think about which parts of your supplier evaluation process can show how your vendors performance can affect your operations the most. Is it on-time delivery? Is it product quality? Or is it how quickly they respond to your needs?


Here are some examples to get you started:

: This shows the percentage of orders delivered on or before the scheduled date.

: This measures the percentage of products or services that don’t meet your quality standards.

: This tracks how long it takes for a supplier to fulfill an order from the time you place it to when it arrives at your home.

: Do they provide all of the Prototyping, Production and post-processing services that you need for this project.

: This indicates how happy you are with the supplier's communication and overall performance.

By setting clear performance levels and ambitious (but realistic) performance goals for each KPI, you will have a good way to measure supplier performance through good supplier evaluations.

Prioritizing Factors: From Reliability to Innovation


When looking at supplier evaluations, some factors matter more than others. It depends on your industry, business goals, and company culture. You need to find the right mix for your company and project needs.


Here are some supplier management factors you might focus on when checking out potential suppliers:

: It is very important to have a supplier who is consistent and dependable. Can you trust them to keep their promises all the time? Do they measure themselves and their vendors on-time performance?

: If your product requires high-quality products or services, it's vital that the supplier is committed to quality assurance excellence.

: Finding a supplier that offers good pricing without affecting quality is usually a main focus.

: For manufacturing companies that want to stay ahead, it is crucial for a supplier to bring modern methodologies and use the latest manufacturing technologies where it makes sense to the shop floor and within the project management teams. They should also be able to adjust accordingly to changes in the market.


Now that you know what to look for, let’s set up a simple 

. Do you remember that useful checklist we made? This will help you stay consistent and compare suppliers fairly. Also, remember that assessing suppliers is not a one-time event! Focus on 

 through qualitative assessments and by planning regular check-ins and feedback meetings with your suppliers.


Steps to Streamline Supplier Assessments


Ready to make your supplier assessments easy? Here’s a simple plan to help you get going:

: Start by collecting all the important information about your potential suppliers. This can include their website, marketing materials, client reviews, and industry reports. Don’t hesitate to ask them directly with a questionnaire for specific details.
2. 

: Use your set evaluation criteria (don’t forget that checklist) to carefully assess each supplier and give them scores based on how they perform.
3. 

: After choosing your top candidates, have detailed talks with them about their Production Methodologies and if they offer Design for Manufacturability (DFM) Reports. This lets you learn more about their strengths, answer any questions, and understand their company culture and communication style better.
4. 

: Based on your assessments, pick the supplier that fits your business needs most. After you make your choice, gather your team to discuss what you learned.

These straightforward steps will help you create a clear and actionable plan to keep your procurement process moving forward.


In conclusion, evaluating suppliers is important for the success and growth of any business. By looking closely at quality, compliance, capacity, and innovation, you can make the evaluation process smoother and build strong partnerships with your suppliers. Be sure to choose key performance indicators, prioritize the important factors, and use technology to stay efficient. Be aware of common mistakes, and always try to create an evaluation process that has a good understanding of your vendor and matches your business goals. Smaller businesses can see great benefits by having a good supplier evaluation plan. This can lead to growth, new ideas, and long-term success. So we hope that you will consider REV A MFG as a potential resource for your product development needs in both Prototyping and Production. Please visit our website for all of our offerings at 

 and if you have questions for us, or need help with supplier evaluations, feel free to ask!


What are the top criteria for evaluating suppliers?


Top evaluation criteria are quality control measures, reliable delivery times, strong financial health, and great customer service. These factors help make sure a supplier can always meet your needs.


How often should supplier evaluations be conducted?

 varies based on your industry and what you need. To have a strong 

, plan for regular checks. These checks can be done every three months, twice a year, or once a year. This helps keep your 


Can small businesses benefit from a structured supplier evaluation
process?

 to make smart choices. This process can lower risks and help create better connections with 

 for an RFQ at quote@revamfg.com or by phone at 760-650-8758

Enhance your supplier evaluation process with our comprehensive checklist.
Streamline your assessments for better decision-making.

Field Notes