Quoteestimator

What this skill does

# 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.

---

## 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
```

---

## 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 |

---

## 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 |

---

## 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 |

---

## 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
```

---

## 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 |

---

## 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 |

---

## Estimation Workflow

### Step 1: Feasibility (Use PlantCapability)
- Can we make it?
- Which machine?
- Any showstoppers?

### Step 2: Operation Breakdown
```markdown
| Op# | Description | Machine | Setup | Cycle |
|-----|-------------|---------|-------|-------|
| 10 | | | min | min |
| 20 | | | min | min |
| 30 | | | min | min |
```

### Step 3: Apply Factors
```markdown
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
```markdown
Setup: [time] × £[rate] = £____
Run: [cycle] × [qty] × £[rate/60] = £____
Material: [weight] × £[per kg] × 1.3 = £____
Secondary: £____
Subtotal: £____
Margin (25-40%): £____
**Quote: £____**
```

---

## Quote Output Template

```markdown
# ROUGH QUOTE ESTIMATE

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

---

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

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

---

## Operations Breakdown

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

---

## Factors Applied

| Factor | Value | Reasoning |
|--------|-------|-----------|
| Material | × | |
| Tol