Howard Klepper had a really good comment on the Perspectives on a Sour Build thread over on AGF. I hope he doesn't mind if I post it here.
Howard Klepper on AGF wrote:
The point is that if I look closely at the guitars made by well-known, top flight luthiers, I can find imperfections on 99% of them, and 99% of those imperfections are trivial. A lot of them are in places on the trim and finish that I know are hard to get perfect, but that the owners might not notice in years of enjoying the guitar. So a line has to be drawn somewhere. This is just another way of saying that everyone, in every industry, works to a tolerance. In some industries this is specified for various parts and given in measurable units. No one has officially quantified any of this stuff for guitars.
The phrase I would use to describe what is and is not acceptable is "within professional standards." This is an evolving standard and may vary with the price and trim level. For example, some ripple in a side, especially right below where the liners go on the other side, is common, but at some point it gets to be too much. Factories have an edge on some processes over hand builders, and getting the sides flat is one place I would expect a little better job from a good factory because their processes are more mechanized, with more costly and heavier duty machinery. I would say the guitar in the photo has too much to meet my expectations for a Style 45 Martin. It does not have too much for a Saga--or for a low to mid priced hand builder.
"Within professional standards" is similar to to the implied legal warranty for any kind of merchandise. I don't remember exactly how the courts word it, but it's something like being fit for its intended purpose and comparable to the work of other persons similarly skilled. Irritatingly vague, huh? But that is considered to be an objective standard in law, and there is a kind of objectivity that is defined by the intersubjective agreement of persons familiar with the art. So how you know whether an imperfection on a guitar is an unacceptable flaw is by asking experienced builders, retailers, and players. If you were in a courtroom it would then be up to a jury. Sometimes consensus is easy, as with the fit of the nut in the thread we are beating to death. At some point between that fit and NASA standards of two surfaces that are machined to align flush with each other, the gap gets too small to be an unacceptable flaw. There will be a grey area where it's hard to call. This is life once luthiers are recognized not to be deities.
__________________
Howard Klepper
I'm finding this discussion fascinating even as a hobby builder with no intentions of going pro... These concepts are not unique to the guitar world. I like Howard's comments because they put it in more realistic and practical terms. I remember sitting through a training seminar by our professional liability company, and they said it was a good idea to avoid claims of "100%" and the like, because it's an unrealistic expectation and you're opening yourself up to problems if you make such claims.
If I were going pro and wanted to realistically hit different price points, I'd figure out how to balance the following factors to meet different price points and still pay myself about the same wage for my time:
1.) Playability (setup, action, intonation, fret work)
2.) Sound
3.) Fit (bindings and purflings, trim work, neck fit)
4.) Finish
5.) Materials
6.) Speed of completion
7.) Choice/Custom features
Playability - I'd say Playability is not negotiable and should be at a high tolerance no matter the price.
Sound - Sound would still need to be held to a high tolerance, but materials would affect this somewhat, and perhaps not quite as much time would be spent tapping and refining for an entry level model. But if it doesn't still sound better than a factory guitar, what's the point.
Fit - I'd say Fit needs to be at a high tolerance regardless of price. A way to economize would be to simplify, eliminate the need for mitering, no purfling, perhaps plastic bindings that are easier to fit well than wooden bindings. Maybe pieces on the inside of the box aren't sanded to as high of a grit, maybe a little glue squeeze out is acceptable if it's not right inside the soundhole?
Finish - maybe think satin vs. gloss finish? Either one, I'd say finish is another area where there's not much room to negotiate as far as the overall quality, but the type of finish could affect price.
Materials - Save the primo zoot for the high end stuff. This is an area where you can set some standard specs so you can take advantage of quantity discounts on regularly stocked material. Also, you can choose materials that are easier to work with, easier to finish, etc...
Speed of Completion - Maybe a lower price point guitar would have a longer completion date, so you could wait till you had enough orders where you could process parts in batches? Just an idea, and may just end up being too confusing to the customer.
Choice/Custom Features - Obviously on a entry level guitar, choices would be rather limited. Obviously you have the most leeway on this aspect, you can offer very few choices to cut the price down. This also saves the time spent making the sale, fewer decisions to discuss and explain.
What do you think? Do you guys consider all this stuff methodically, or do you feel it out more based on experience?