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cats? 30" Versacam? Daige?
You can't be serious about building a production workflow... Sounds more like you want to get get away with spending the least amount of money possible (undercapitalized).
No offense intended, but why do you want to use the cheapest possible tools to produce your designs?? Find the BEST possible tools, not the cheapest.
The setup you recommend (30" VC, Daige, Rotary cutter (hehe), and CATS!) makes it sounds like you are working out of your living room and doing no volume. You also have no money. The rig you describe is perfect for this kind of business (low volume, home biz). But...these tools are not the best in their breed. I think the 64" Valuejet, Onyx RIP, Graphtec 7000 cutter, Seal/Royal Soverign laminator, Safety Speed Cut panel saw, and a Juki 1541 sewing machine to be a great start-up tool list. With these tools you are not compromised at all and can tackle 90% of the non-electrical sign work out there. The thing is that you need about 40k plus a shop to put it in. Then you need work tables, computers, supplies (ink, vinyl, substrates, etc). You need hole punchers, corner rounders, material storage solutions, etc... After all this a customer walks in and wants to buy 50 yardsigns for $99 like he saw on "cheapasssigns.com".
Oy Vey! All this increase in costs but no guarantee in increased revenue.
Production retail sign shops do not have cats. They have a print/vinyl room, a wood shop, paint room, They have 54-64" ecosol printers (or better). Aqueous ink jet printers are better for certain jobs. Many have flatbed printers to print directly on substrates. All laminate. Many have panel saws, cnc routers, table saws, laser cutters, welders, grinding tools. Many have a truck bay. etc.... and on and on.
My advice is to seriously write a business and marketing plan. What is your cash flow? Identify who your customers are. How you are going to reach them. Who do they buy from now. What are you going to sell them. How will you manufacture & deliver the product. What are your competitive advantages over your competition... and disadvantages. What volume of business can you handle with current manufacturing capacity? If you expand manufacturing capacity, or add a mfg process, what level of business will you expect to add? Will that increase in business be profitable enough to offset the increased capital expense??
There are a million more questions you need to be asking yourself. If you are spending $4-5K a month for wholesale printing THEN you should consider taking that process in house.
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