Every new product requires a specific level of quality that businesses must factor into their budget. For everyday consumer goods, this might mean ensuring a part works just long enough to outlast the warranty period or achieving the highest level of quality possible for a given price.
But for Ben Machine customers, the expectations are a little different. Our parts must function in outer space, military vehicles, medical systems, and even within nuclear reactors. Failure isn’t just costly—it’s catastrophic.
That’s why quality isn’t just a buzzword in our shop; it’s a business necessity. We’ve built our entire operation around meeting the extreme demands of mission-critical industries. However, doing so comes with a price—not just for us, but also for our customers.
This is where the concept of the “cost of quality” comes into play. In manufacturing, it refers to the total cost of achieving and maintaining quality—both the cost of doing things right (prevention and inspection) and the cost of things going wrong (scrap, rework, and warranty issues).
In this article, we’ll break down what goes into the cost of quality in CNC machining and show why investing in quality upfront is almost always the smarter—and more cost-effective—choice.
What Is the Cost of Quality in CNC Machining?
The cost of quality isn’t just about how much it costs to make a perfect part. It includes every cost tied to quality across the production lifecycle—both good and bad. These costs are typically grouped into four categories, each with a direct impact on your bottom line:
1. Prevention Costs
These are the costs associated with preventing problems before they occur. In CNC machining, that includes:
- Staff training and skills development
- Equipment calibration and maintenance
- Certification processes (e.g., ISO 9001, AS9100)
- Engineering time spent on manufacturability analysis
Ben Machine invests heavily here. We know that preventing defects is always cheaper than correcting them.
2. Appraisal Costs
Appraisal costs represent the inspection and testing of parts to catch defects before they leave the shop. In our case, it means:
- Running parts through our CMM machines
- Using integrated CAD/CAM systems to verify specs
- Assigning 10% of our workforce to quality control
Although these costs might seem high, they are only a fraction of what downstream failure would cost.
3. Internal Failure Costs
These are the costs of catching and fixing mistakes before the part reaches the customer. For example:
- Scrapped raw materials
- Labour costs for rework or adjustment
- Machine downtime
As one of our team members put it, “There are costs associated with having to rework parts you don’t have to have if the parts are done correctly from the beginning.”
4. External Failure Costs
This is where things get really expensive. These are the costs that hit when a bad part makes it into the field:
- Warranty claims
- Product recalls
- Lost customers
- Brand reputation damage
In short, cutting corners on quality is rarely a true saving.
Why Quality Isn’t Just About Efficiency
It’s easy to assume that high efficiency equals high quality—but they’re not the same thing.
As one of our engineers puts it: “Efficiency is how fast we do things; quality is how well.”
You can be highly efficient and still produce bad parts. Conversely, a slower process with proper controls might yield better outcomes. The goal isn’t just to be fast or cheap—it’s to be right.
On paper, cutting cycle times or reducing setups might look efficient, but if it leads to inconsistent tolerances or missed specs, the downstream costs can be significant. True efficiency is measured over the entire lifecycle of the part—not just how fast it’s made, but how reliably it performs once it’s in use.
For decision-makers, that matters. A faster quote or lower upfront cost can lead to delays, complaints, and extra costs when those parts don’t perform. That’s why the best CNC machining partners focus on quality first. It’s a smarter long-term investment.
The True Costs of Poor Quality
Poor quality in CNC machining doesn’t just result in a few bad parts—it can create a ripple effect that drives up costs across your entire operation. Here’s a breakdown of where those costs can creep in.
Internal Costs
Even before a flawed part leaves the shop, it’s already racking up costs:
- Scrapped materials: Precision materials aren’t cheap, and wasted stock adds up quickly.
- Rework labour: Fixing flawed parts ties up machines and labour that could be working on new orders.
- Production delays: Time spent correcting mistakes can put entire production schedules behind.
At-Customer Assembly Stage
If a bad part makes it past inspection, the impact grows:
- Integration issues: Non-conforming parts can throw off tolerances in assemblies.
- Production line delays: A bad component can shut down or delay an entire customer line.
- Expedited fixes: Emergency shipping and remanufacturing are costly.
Post-Deployment / Field Costs
This is where the damage really compounds:
- Warranty repairs: Replacing parts in the field is expensive and logistically complex.
- Safety concerns: In defence, medical, or aerospace applications, failure can be life-threatening.
- Lost customer trust: One bad part can lead to lost business—or a damaged reputation that’s hard to repair.
As one of our managers pointed out: “A 10% scrap rate can lead to a 25% increase in total product cost. The cost to repair often outweighs the cost of doing it right the first time.”
Ben Machine’s Investment in Built-In Quality
At Ben Machine, we don’t treat quality as a final check—we build it into every step of our process.
- 10% of our team works in quality control and metrology
- CMM machines worth $100,000 to $500,000 are used to inspect critical parts
- CAD/CAM-integrated metrology ensures specs aren’t just met—they’re traceable
- 5- and 6-axis measurement tools verify complex geometries
- ISO 9001 and AS9100 certifications are maintained and audited regularly
- ITAR-level security protocols are applied for sensitive contracts
These investments aren’t just about compliance—they’re proactive quality strategies. We work in industries where failure isn’t an option. Aerospace, defence, nuclear, and medical sectors demand near-zero defect rates, and we’ve built our operations to deliver just that.
Smart Sourcing and the Real Cost of Materials
Material choice plays a significant role in the cost of quality. And it’s not just about price per pound—it’s about what that price protects you from.
Take material sourcing, for example. Do we go with the cheapest overseas supplier, or spend a bit more to source from a trusted domestic partner? The answer depends on risk.
Cheap materials often come with:
- Longer lead times
- Shipping delays and customs issues
- Uncertain certifications and traceability
When you’re dealing with mission-critical applications, those risks aren’t worth the savings. A few dollars saved on stock could cost thousands in delays or rework.
We also look at material efficiency. If our engineers can design for less waste, we can afford to spend a bit more on higher-grade stock. Similarly, choosing a 5-axis CNC machine over a cheaper 3-axis setup can reduce the number of operations and cut total labour hours—another hidden source of cost savings.
Smart sourcing is just another way we manage the cost of quality.
Technology and Strategy Behind Quality
Technology plays a huge role in how we deliver both high quality and operational efficiency.
- Advanced CNC machines (including 5-axis) let us do more in a single setup, reducing manual labour and the risk of error.
- Integrated digital tracking systems ensure every part is documented, traceable, and verified.
- Engineering involvement early in the process—design for manufacturability—helps avoid costly design changes later.
Ben Machine isn’t just a vendor. We’re a machining partner that helps you find long-term, reliable ways to get your parts done right.
Conclusion and Call to Action
In the final analysis, investing in quality upfront always pays off. The true cost of quality in CNC machining includes more than what’s on the quote—it’s also what happens if the parts don’t meet the mark. Delays, rework, and unhappy customers all add up fast.
At Ben Machine, we’ve made deliberate choices to focus on quality where it matters most. We maintain extensive quality assurance systems, invest in certifications and metrology, and specialize in precision machining for sectors where there’s no room for failure.
We focus on low-volume, high-precision production and prototyping. And after 50 years in the industry, we know how to develop processes that other shops can’t figure out. Whether you’re working on a first-run prototype or a mission-critical component, we bring the same level of care to every part we touch.
So, rather than assuming Ben Machine is too specialized for your project, reach out to us. Let us take a look at your next project—we’re confident we can deliver the quality you need, at a value you didn’t expect.
