tcg,
May I suggest something _
Back in the 60s when the RAF took over the RN Buccaneers and was getting the Phantom they liked the RN designed strike-rule. They went to the LNMCo, and were asked how many they wanted. A quick finger count, number of aircraft, number of aircrew, number of spares, and came up with 500 or so.
Like you they were told that the minimum order was measured in DAYS not quantity. The major cost being the setup and the cleanup. In a day some 100,000 could be produced.
Same problem you found.
Now the suggestion. If you can afford it, then order the minimum quantity and then SELL the surplus.