Impact of setup optimization to understandable cost logic.
The following two graphs clearly illustrate the principles described above and help translate technical processes into understandable cost logic.
Graph 1 – Fixturing optimization
This graph shows how an improved setup system reduces preparation time step by step:
basic clamping → standardized setup → dedicated fixture → repeat production
As the setup method evolves, preparation time shifts from a development-style task to a nearly routine operation.
This represents the transition from manual workshop work to an industrially repeatable process.
In practical terms, the operator no longer needs to “figure things out” for each run — the process becomes predefined, controlled, and fast.
Graph 2 – First production run vs. repeat batch
From a business perspective, this is the most powerful visualization.
It highlights three key facts:
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The first production run carries the full setup and preparation cost
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In repeat production, setup effort is minimal
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The unit price decreases without any change in machining time or material
This demonstrates that the savings come purely from process maturity and repeatability, not from cutting corners.
Customers quickly understand why long-term production cooperation is more cost-efficient than one-time orders.