Il tema dei costi di produzione è sempre molto controverso e mi rendo sempre più conto che gran parte delle aziende non ha chiaro questo aspetto, o meglio, ovviamente sa che esiste, ma non viene utilizzato correttamente come strumento.
Partiamo da un presupposto ormai assodato (almeno si spera):
“Il costo del macchinario non è mai un problema”.
Aspetta, non fraintendermi.
Questa è sicuramente una dichiarazione che a molti operatori del settore potrebbe suonare come un’assurdità, eppure non è così e più avanti ti spiegherò perché.
Prima di comprendere perché il costo del macchinario non è mai un problema, è necessario fare un passo indietro e sapere esattamente come sono strutturati i costi quando si effettua un acquisto.
Il prezzo di acquisto, per assurdo, è l’ultimo elemento di cui dovremmo preoccuparci.
Costi diretti e indiretti per il calcolo del TCO
Per prima cosa bisogna fare una netta separazione tra:
- Costi diretti (evidenti e noti)
- Costi indiretti (nascosti)
Per “costi diretti” intendiamo i costi noti di produzione, che sono quelli facilmente imputabili a una determinata attività o centro di costo e che quindi risulta semplice individuare e quantificare.
Nel 90% dei casi tali costi sono anche gli unici che vengono presi in considerazione.
Questo è dovuto principalmente a un bias cognitivo del nostro cervello, che tende a dare più peso e importanza a ciò che vede e può toccare con mano, escludendo o dando meno importanza a elementi “meno evidenti”.
In gran parte dei casi però, questi sono i più significativi.
Ma ora veniamo ai “costi indiretti”, che invece sono quelli che possiamo definire come costi nascosti di produzione, ossia quelli di più difficile individuazione e che non è sempre semplice quantificare e attribuire alle rispettive attività e centri di costo.
Prima di fare un investimento in nuovi macchinari è importante saper padroneggiare questi due ingredienti, così da fare le scelte di investimento migliori e poter ottenere un miglior ritorno economico.
La somma di queste due macro famiglie di costi porta a comprendere meglio la convenienza di un acquisto rispetto a un altro.
Ma soprattutto, grazie ad essi, è possibile calcolare un indicatore oggi essenziale per la scelta degli investimenti nei reparti di produzione.
Parliamo del TCO, il Total Cost of Ownership.
Senza questo indicatore risulta veramente difficile avere la capacità di fare le scelte corrette e la probabilità di commettere errori è molto più elevata.
TCO: che cos’è e perché è l’indicatore dei tuoi investimenti in produzione
Per TCO (Total Cost of Ownership) intendiamo il Costo Totale di Possesso di un bene.
È una metodologia di valutazione dei costi in uso nell’ambito di beni durevoli, macchinari industriali compresi, che permette di avere un quadro completo di medio-lungo periodo su tutti i costi e flussi di cassa che bisognerà affrontare all’acquisto di un determinato bene A rispetto a un altro determinato bene B.
Perché mi preme sottolineare “medio-lungo periodo”?
La risposta sta nel fatto che non è assolutamente sensato fare una semplice analisi di breve periodo, rivolta unicamente al prezzo di acquisto del bene, in quanto questo dato dice poco o niente su tutta una serie di altri costi che scaturiranno dal quel determinato acquisto.
Bisogna porsi le giuste domande:
- Cosa comporterà acquistare questo macchinario?
- Quali costi dovrò affrontare per le attrezzature?
- Di quanto personale avrò bisogno per gestirlo?
- A quanto ammonteranno i costi di manutenzione annui?
- Per quanto tempo potrò utilizzare tale macchinario?
- Entro quanto riuscirò ad ammortizzare il costo, in funzione della capacità produttiva?
E così via…
Queste sono solo alcune delle domande che dovresti porti.
E queste domande sono quelle che noi, grazie a metodi di valutazione e quantificazione ben precisi, utilizziamo nel Porta Production Method e ci permettono di determinare il TCO dell’investimento in questione.
Per comprendere ancora meglio il concetto del Total Cost of Ownership voglio mostrarti questa immagine:
È un’immagine che in pochi secondi rimanda in maniera iper semplificata ciò che ci serve comprendere per definire il TCO.
Nel 90% dei casi, le persone alla ricerca di una nuova automobile si focalizzano solo sul costo di acquisto, dando un peso veramente ridotto a tutta una serie di costi che comunque dovranno affrontare per mantenere l’auto (assicurazione, bollo, consumi, altro…).
Eppure è noto che gran parte del costo di un’automobile è rappresentato dai vari sotto costi che scaturiscono dal POSSESSO della stessa.
Ecco, nel mondo delle Macchine Utensili è la stessa cosa e il prezzo di acquisto è la voce che teoricamente dovrebbe pesare meno nel processo di valutazione dell’investimento.
Ecco perché ho esordito dicendo che
“Il costo del macchinario non è mai un problema”.
Proprio perché molto spesso una Macchina Utensile più costosa, se valutata correttamente in un’ottica di medio-lungo periodo, può risultare più conveniente e meno costosa rispetto a soluzioni e macchinari con prezzi di vendita nettamente più bassi, ma che nascondo costi invisibili che erodono il profitto nel medio termine.
Questo è il TCO ed è bene saperlo padroneggiare, soprattutto se sei un utilizzatore di Centri di Lavoro.
A proposito di Centri di Lavoro…
Il TCO applicato al mondo dei Centri di Lavoro e delle Macchine Utensili
Compresi i concetti sopra esposti, vorrei ora concentrare l’attenzione sul mondo delle Macchine Utensili e in particolare sui Centri di Lavoro.
La comparazione che voglio proporti è tra i Centri di Lavoro in batteria e le Macchine Utensili a 3 mandrini indipendenti.
Ovviamente la Macchina a 3 mandrini indipendenti ha un prezzo di acquisto superiore rispetto al singolo Centro di Lavoro, ma fermarsi a questo numero non permetterebbe alla tua azienda di conoscere la verità nascosta dietro a queste due opzioni di investimento.
I punti da valutare quando si acquista una Macchina Utensile sono:
- COSTO DELLE ATTREZZATURE
- COSTO DI AUTOMAZIONE
- COSTO DEL PERSONALE SPECIALIZZATO
- COSTO DI ENERGIA
- COSTO DEGLI SPAZI OCCUPATI
Le Macchine Utensili a 3 mandrini indipendenti sono molto più produttive rispetto ai Centri di Lavoro, inoltre sono progettate per cambi rapidi di produzione (in 15 minuti), quindi risultano avere un TCO nettamente inferiore.
Qui sotto è riportata la comparazione tra 3 Centri di Lavoro in batteria e 1 PORTACENTER a 3 mandrini indipendenti di Porta Solutions S.p.A.
Il PORTACENTER ha una capacità produttiva superiore a 3 Centri di Lavoro in batteria.
Questo permette di affrontare al meglio la sfida della produttività, con cambi di produzione in 15 minuti che abbattono il tuo costo pezzo!
La soluzione a 3 mandrini indipendenti permette di effettuare, in un unico bloccaggio pezzo, un ciclo di lavoro più veloce mantenendo un unico processo produttivo.
Con 3 Centri di Lavoro in batteria hai 3 processi da tenere sotto controllo e il tuo CPK risulterà dalla media di questi 3 processi.
Questo, insieme alla velocità di produzione (nettamente superiore nel PORTACENTER), permette di avere meno macchine in produzione, meno personale, meno costi nascosti.
MENO MACCHINE = MENO COSTI
Ed ecco che, per investimenti ed esigenze produttive dove serve essere più competitivi, il TCO di una macchina a 3 mandrini indipendenti con un solo processo, come il PORTACENTER, è nettamente vantaggiosa rispetto ai Centri di Lavoro in batteria.
Perché il TCO nelle Macchine Utensili a 3 mandrini è nettamente inferiore
Ora vediamo i vantaggi e il motivo per il quale le Macchine Utensili a 3 mandrini indipendenti con un processo produttivo permettono di abbattere il TCO e quindi anche il costo pezzo:
- ATTREZZATURE, 4 staffaggi per 1 PORTACENTER contro 48 staffaggi per 3 Centri di Lavoro.
- AUTOMAZIONE, un solo robot anziché 3.
- PERSONALE SPECIALIZZATO, con 1 PORTACENTER l’addetto dedicherà il 33% del suo tempo alla gestione del macchinario, rispetto al 100% del tempo da dedicare per gestire 3 Centri di Lavoro in batteria.
- SPAZIO OCCUPATO, con 3 Centri di Lavoro in batteria lo spazio occupato è nettamente superiore.
- ENERGIA, avere 1 solo macchinario a 3 mandrini permette di abbattere i costi di energia, molto alti invece nei reparti con tanti Centri di Lavoro in batteria.
CLICCA QUI PER VEDERE IL VIDEO DI COMPARAZIONE
PORTACENTER VS CENTRI DI LAVORO
Ora che hai capito cos’è il TCO – Total Cost of Ownership è importante agire e fare in modo che, dai prossimi investimenti in nuovi impianti e Macchine Utensili, tu riesca a trarre il vantaggio migliore per avere più margine di profitto da reinvestire in azienda.
La scelta di acquisto di una nuova Macchina Utensile è un’operazione delicata in cui non sono ammessi errori, perché uno sbaglio potrebbe compromettere il futuro della tua azienda per sempre.
Proprio per questo motivo ho sviluppato il PORTA Production Method, un metodo collaudato e che, step by step, ti permette di massimizzare i risultati dei tuoi investimenti in nuove macchine utensili.
Questo anche grazie al supporto di un team di Tutor Tecnici di grande esperienza, che ti guideranno nell’analisi del tuo reparto di produzione, per individuare la scelta migliore per la tua azienda.
Ora tocca a te!
Vuoi continuare a fare investimenti sbagliati, pensando che il prezzo di acquisto del macchinario sia l’unica cosa che conta?
Oppure vuoi finalmente fare tuo il calcolo del TCO per massimizzare i margini di profitto e i risultati di medio-lungo periodo per la tua azienda di produzione?
RICORDA: Il costo del macchinario non è mai un problema!
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Telefono: +39 030 800673
Email: info@portaproduction.com
Per approfondire il tema delle Produzioni Competitive e il PORTA Production Method
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