How to reduce cost without reducing quality: optimisation for production

The baseline principle: cost = material + time + risk

In scaled jewellery production, cost increases due to:

• too many operations,
• variability (too many variants),
• rework due to tolerances,
• and finishes that are hard to sustain in series.

Optimisation levers (without lowering the standard)

1) Design for manufacture (DFM)

• Avoid extremely thin areas if they don’t add visible value.
• Reinforce stress points (clasps, joints, prongs).
• Simplify geometry that forces rework.

2) Reduce variants in the first lot

• Launch with 1-2 primary finishes.
• Limit sizes/colours and scale later.

3) Set tolerances to what’s necessary

“Perfect” tolerances cost money. Define:

• where it matters (clasp, fit),
• and where it doesn’t (non-critical areas).

4) Pick the right process

• Suitable parts benefit from more stable processes at volume.
• Frequent design changes favour more flexible processes.

5) Smart setting (if applicable)

• Design seats and prongs to reduce manual intervention.
• Standardise stone calibres.

6) Series-friendly finishing

• Avoid finish combinations that require masking and reprocessing.
• Agree realistic visual standards.

What we need for an optimisation review

• CAD/key dimensions + reference photos
• Priority: cost vs quality vs speed
• Target quantity and forecast
• Non-negotiables and critical areas