Converting Job Quote Cost Build-Up Worksheet
A good converting quote is built operation by operation, not from a blended rate. This worksheet lets you list each step, its setup hours, run speed, hourly rate and materials, then rolls it up to total cost, cost per thousand and a price at a chosen margin.
| Operation | Notes | Setup hours (hr) | Run quantity (units) | Run speed (units/hr) | Machine plus labor rate ($/hr) | Material and outside cost ($) | Run hours | Total hours | Operation cost | |
|---|---|---|---|---|---|---|---|---|---|---|
0 | 1.5 | $548 | ||||||||
5 | 7.5 | $4,388 | ||||||||
3.3333 | 4.0833 | $1,028 | ||||||||
4 | 5.25 | $958 | ||||||||
2.5 | 3 | $210 | ||||||||
2 | 2.25 | $318 |
Enter the finished quantity as the largest run quantity so cost per thousand is right. A speed of 1 with quantity 0 gives a pure setup row. Machine rates should come from your own burdened cost per hour. Margin shown is a gross margin on price, not markup.
Turn routings into instant quotes
Optional: review how your ERP routings, rates and material costs could populate a quote like this automatically.
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How to use it
Start from the routing: prepress, printing, lamination, die cutting, slitting or gluing, inspection and packing. For each, enter setup hours, the run quantity in that operation's units, the run speed in units per hour and your burdened rate per hour. Add materials and outside services in the last input column. Hours and cost compute per row, and the totals update. Add rows for anything else, such as outside finishing or freight, and delete the ones that do not apply.
The method behind the numbers
Operation cost equals setup hours plus run quantity divided by speed, multiplied by the rate, plus material. Gross margin price equals cost divided by one minus the margin fraction. This differs from markup: a 30 percent markup on cost is only a 23 percent margin. Use the same method for every quote so that pricing differences come from the job and not from the estimator.
Worked example
The default rows describe a 30,000 unit job. Printing adds 2.5 setup hours plus 5 run hours at 165 dollars per hour, plus 3,150 dollars of film and ink. The rest of the routing adds smaller operations. The summary shows the total cost, cost per thousand and a price per thousand at 30 percent gross margin. Change one speed or setup and watch how much of the price moves.
Common mistakes
Typical errors include quoting run speed from machine spec sheets rather than achieved speed, leaving out waste in the material line, ignoring that short runs are dominated by setup, and using a single rate for every machine. Review actual speeds from the shop floor regularly, and keep a separate waste line for printing and die cutting.
- Use achieved speeds, not nameplate speeds
- Add waste to material quantities before pricing
- Quote price breaks by changing quantity and keeping setup fixed
Frequently Asked Questions
How do I handle waste in this worksheet?
Increase the run quantity of each operation by the expected waste, or add a material line that includes it. For example, printing 30,000 good units at 5 percent waste means running 31,500 units. Keep waste lines visible so you can improve them.
What machine rate should I use?
Use your burdened cost per hour: labor, depreciation, power, maintenance, space and overhead allocated to that machine. Do not use selling price per hour. Your controller or standard cost roll-up usually holds the right figure.
Why is the margin different from markup?
Margin is profit divided by price, markup is profit divided by cost. A 30 percent gross margin requires dividing cost by 0.70, a markup of about 43 percent. The worksheet uses margin.
Can I quote price breaks?
Yes. Copy the worksheet, change quantities, and keep setup hours fixed. The cost per thousand falls as setup is spread over more units. Compare the results to build a price break table.
If your estimators rebuild this routing from memory every time, we can connect routings, rates and achieved speeds in your ERP to a quoting assistant that runs on your own servers.
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