Too often, great design ideas like yours never go beyond a working prototype – simply because of budget. Tooling and manufacturing costs are just two of many factors that can stop a project from progressing to market. But at Bluefrog Design we don’t let these things stop us – in fact, we’ll help you do the best with your budget. The choices you make, rather than the chances you take, will determine the success of your product. You may ask yourself ‘How can I reduce my manufacturing costs?’. Choosing the right industrial design agency is just the first step and it’s one we can help you with.

As a product design and development company, our people-based approach to design innovation is dedicated to your business and tailored to your needs. We genuinely care about the end-users and are committed to making products for people to help people and we want the best for our clients – that means you too! We are a multi-disciplinary professional design consultancy that combines transferable design and engineering skills to innovate product design and visualise your project from start to finish, from your initial idea through to prototype and finished product from an aesthetic and practical angle. We think in-depth about your product and how to make it appropriate to the market. We understand that the right processes, design methodology and materials especially those related to mechanical engineering, are critical to production. It’s where our expertise lies and here’s how we can help you reduce your manufacturing costs and improve productivity:

Manufacturing is an industry that’s changing rapidly and daily. New software and innovative technologies are transforming our capabilities as well as the speed and cost of manufacture. We keep up to date with these so that you have the best choice of options for your product. But our commitment doesn’t stop there. We look beyond your brief and at the bigger picture. From our first conversations with you, we develop a unique product design specification to analyse what’s required to bring your ideas to life, to identify constraints and highlight opportunities. We empathise and are sensitive to your design ideas and work with you to deliver a successful outcome. We understand the pitfalls and challenges in the creation of an innovative product. Why? Because we’ve overcome them time and again, not only as designers but also as manufacturers ourselves. We apply design expertise with practical experience to ensure your products are produced economically, environmentally and realistically.

A huge saving in cost and production time can be achieved simply by choosing a different method of manufacture. For example, injection moulding is often viewed as the best process of manufacture for complicated designs, but the relatively high tooling costs rarely deliver a return on investment for low volume production – often quantified in hundreds rather than thousands. In this situation we can help you find alternative manufacturing solutions, such as RIM (Reaction Injection Moulding), vacuum casting or even 3D printing, all of which are capable of producing parts in a range of materials and properties at significantly lower levels of investment – bridging the gap between low, medium and high-volume manufacturing. However, injection moulding becomes viable as quantities rise into the thousands where the trade-off between tooling investment and improved productivity reduces the overall component and finished costs.

At Bluefrog Design, we understand our clients and know what you need to achieve your design goals. We want you to be successful and share the same ambition of launching products into production and helping sales fly off the shelves. Our clients trust us and advise us of their budgets – knowing this information is paramount to us making cost savings and suggesting alternative production processes. For example, modular construction methods could benefit those clients looking to produce a range of items. Although each product is individual, its parts could easily be shared on an assembly line to reduce time and inventory costs. Remember, it’s easier for your design agency, as a third party, to see where potential savings could be made. Often when you’re so close to something, you need other voices to allow you to stand back and gain perspective.

Manufacturing costs are the total expenses involved in the production of goods, and they’re pivotal for pricing strategies and profit analysis. These costs are categorised into direct materials, direct labour, and manufacturing overhead. Direct materials are the raw components used in the product, while direct labour encompasses the wages of employees who assemble the product. Manufacturing overhead covers indirect costs like maintenance, utilities, and equipment. Accurately calculating these costs ensures competitive pricing, informs financial planning, and drives efficiency in production operations, which can lead to increased profitability and cost-effective resource utilisation.

Reducing manufacturing costs is crucial for businesses to enhance their competitiveness and profitability. Lower production costs can lead to more aggressive pricing in the market, offering a price advantage over competitors. It also allows companies to maintain reasonable profit margins even when facing price pressures. Additionally, cost reductions can free up resources for investment in innovation, quality improvement, and expansion. Streamlining manufacturing processes improves efficiency and productivity, which can result in faster turnaround times and better customer satisfaction. Ultimately, reducing manufacturing costs is key to a company’s financial health and long-term sustainability in a competitive landscape.

To reduce manufacturing costs effectively, companies can adopt lean manufacturing principles to eliminate waste and optimise production flow. Investing in automation and advanced manufacturing technologies can improve efficiency and reduce labour costs. Regular maintenance of machinery ensures peak performance, avoiding costly downtimes. Outsourcing non-core activities can also reduce costs, allowing focus on key competencies. Bulk purchasing of raw materials often results in lower prices, while careful inventory management minimises holding costs. Training employees to multi-task can increase flexibility and productivity. Lastly, constantly reviewing and improving the production process can lead to ongoing cost savings and quality enhancements.

Calculating the cost of manufacturing requires totaling all expense factors involved in the creation of a product. Start by adding direct material costs, the price of all raw materials used. Then include direct labour costs, which account for the wages of workers directly involved in manufacturing. Overhead costs, which are indirect expenses like utility costs, rent, and equipment depreciation, are then allocated to each product based on a predetermined overhead rate. For a more precise cost, consider adding expenses for quality control, packaging, and logistics. Summing these figures provides the total manufacturing cost per product unit, essential for pricing and profitability analysis.