A prototype proves that your enclosure works. Series production decides whether it pays off. We show how unit costs fall in medium and high volumes, when a blanket order makes sense and how the thousandth enclosure stays as accurate as the first.
Once ten enclosures turn into five hundred or five thousand a year, the questions change. What does an enclosure cost at which quantity? How do parts reach your warehouse on schedule? And how does the thousandth part stay as accurate as the first?
Since 1975, KRIEG has manufactured metal enclosures, cabinets and sheet metal assemblies to customer specifications, from one-offs to high-volume series. In this guide we explain what matters in series production and how your design and order planning influence your unit costs.
Small, medium or high volume: what is the difference?
Our rule of thumb at KRIEG: small volume means 1 to 50 pieces, medium volume 50 to 500 pieces, and from 500 pieces we speak of high volume. These are not fixed limits, because it depends on how large the end product is. 300 large control cabinets are a very different task from 300 small electronics enclosures.
| Small volume | Medium volume | High volume | |
|---|---|---|---|
| Typical quantity | 1 to 50 pieces | 50 to 500 pieces | 500 pieces and more, often called off regularly |
| Set-up share of unit price | high | much lower | low |
| Order type | single order | single or blanket order | blanket order with call-off schedule |
| Production | flexible, no special tooling | fixed batch sizes, stored programs | established routines, fixtures, fixed cycles |
| Typical applications | prototypes, special machinery | controls, devices, mechanical engineering | series devices, high-volume electronics enclosures |
Why unit costs fall as volumes grow
Every enclosure carries two kinds of cost. First, the effort incurred for every part: material, machine time, coating, assembly. Second, the effort incurred once per batch: programming the punch-laser machine, setting up the press brake, colour changes in powder coating, first-article inspection. These set-up costs stay the same whether we make 20 or 2,000 enclosures. The larger the batch, the smaller their share of each enclosure. Economists call this fixed cost degression.
The curve drops steeply at first and then flattens out. That is exactly where medium volume sits: most of the savings are achieved, yet production stays flexible. Part-specific tooling such as a progressive die lowers the cost per part further. But it often costs a five-figure sum up front, so it usually only pays off at very high, stable volumes without design changes.
The second lever is the batch size per call-off. If you need 2,000 enclosures a year but order 40 every week, you pay for set-up 50 times. With a blanket order we produce in economical batches and still deliver exactly the quantities you need.
Series without special tooling: punch-laser instead of dies
For enclosures in medium and high volumes we rely on machines that work without part-specific tooling. Our four TRUMPF TruMatic 7000 combine punching and laser cutting in one machine: the laser cuts the contour, while hole patterns, extrusions and embossing are made with standard tools. The active die ensures scratch-free surfaces, which matters for powder-coated visible faces. Two laser machines, a TruLaser 3030 and a 5030, complete the line-up.
The program for your enclosure is stored and runs identically at the next call-off. Because several identical machines are available, a series order can run in parallel or switch to a sister machine during maintenance. That makes delivery dates reliable.
The process chain: everything under one roof
A metal enclosure goes through many steps before it reaches you. At KRIEG they all take place in one 16,500 m² plant in Heinsberg, Germany. For your series this means no transport to subcontractors, no waiting between two companies and one contact for the complete enclosure.
15 manufacturing steps in total, all in Heinsberg.
Samples before series: inspect first, then produce
Before series production starts, we offer you samples. You hold your enclosure in your hands, fit your electronics and see the surface and colour in the original, before 500 parts are made. If anything needs changing, it now costs one new sample instead of a whole series.
- 1Make the sampleTo your drawing, using the same processes as the later series.
- 2You inspectFit, assembly with your components, surface and colour.
- 3ApprovalYour OK makes the sample the binding reference.
- 4Series startSame programs, same inspection characteristics, delivery as planned.
- Dimensions and fit
- Assembly with your electronics
- Hole patterns and press-in parts
- Surface and RAL colour
- Screen printing and labelling
- Packaging and handling
Because we work without part-specific tooling, a sample is quick to make, and a change does not mean new tooling. With your approval, the sample becomes the standard for every later delivery.
Blanket orders and call-offs: deliveries you can plan
In high-volume production most customers do not order each delivery separately. They agree a blanket order: an annual quantity, a fixed unit price for the term and a call-off schedule. We turn this into economical production batches. By arrangement with you, we also hold a stock buffer that secures your call-offs, so that even short-notice extra quantities are no problem.
- price and capacity secured for the term
- less ordering effort
- less storage space on your site
- economical batch sizes
- predictable machine scheduling
- lower unit costs that reach you
Deliveries go out with our own fleet: two articulated lorries, three trucks and two vans supply customers within a radius of around 350 km directly. Why delivery reliability matters so much for your production is explained in our article Delivered on time or stranded?
The same quality for the first and the thousandth enclosure
Series quality means every enclosure matches the drawing and the approved sample, delivery after delivery. Three things make sure of that:
- The approved sample sets the standard
What you approved on the sample is the reference for every delivery. Exactly this status goes into series production.
- Fixed programs and inspection characteristics
Punching, bending and welding programs are stored. We check the characteristics from your drawing in every production step, see quality assurance.
- Documented and traceable
Our own CAQ software and barcode portal record which batch was produced and inspected when. Certified to DIN EN ISO 9001:2015.
How to make your design series-friendly
The design comes from you, and we never change it without your consent. From experience, though, we know which details save time and money in series production. Our engineering office points them out when reviewing your enquiry. The decision stays with you.
One radius for all bends saves tool changes on the press brake.
Common gauges are available faster and cost less to buy.
Press-in nuts and studs are fitted quickly and need no rework.
Same base body, differences only in cut-outs or printing: many small batches become a few large ones.
Tight tolerances only where the function requires them. That saves inspection effort on every part.
One colour for several parts means fewer colour changes in powder coating.
Which documents we need for a fast quote is shown in our checklist From drawing to quote.
You provide the design and the demand. We provide the right production concept, consistent quality and enclosures that arrive on time.
Frequently asked questions about series production of metal enclosures
From what quantity is it called medium volume?
Our rule of thumb at KRIEG: small volume 1 to 50 pieces, medium volume 50 to 500 pieces, high volume from 500 pieces. The limits depend on how large the end product is.
Do I need dedicated tooling for high-volume production?
Usually not. With punch-laser technology and standard tools we produce large quantities without part-specific tooling. Special tooling only pays off at very high, stable volumes without design changes.
What is a blanket order with call-offs?
You agree an annual quantity and a price for the term and call off partial quantities as needed. We produce in economical batches and deliver on your call-off dates.
Do I get a sample before series production?
Yes. Before series production starts, we make samples to your drawing. You check fit, assembly and surface and approve them. Only then do we start the series.
Does KRIEG manufacture to my own drawing?
Yes. We manufacture to your drawing and CAD data. Our engineering office checks manufacturability and gives advice. The decision about your design stays with you.
Which surface finishes are available in series?
Powder coating in RAL colours on our automatic NORDSON line, plus further surface treatments and screen printing for labels and logos.
How quickly can a series call-off be delivered?
That depends on the enclosure, the quantity and the agreement. With a blanket order and call-off schedule, delivery dates can be planned reliably. Within a radius of around 350 km we deliver with our own trucks.
Can the quantity be increased later?
Yes. Because we work without part-specific tooling and run several identical machines, production grows with your demand: from small volume to medium volume to high volume.
Send us your drawing and annual demand.
We review your enclosure, suggest sensible batch sizes and calculate your series price.
