Three steps to optimizing machining
To profitably machine high-quality parts, many manufacturers follow a similar path, beginning with tool selection and application and then solving any problems that arise in a reactive way. However, research suggests that manufacturers should examine the entire machining process before cutting begins, focusing on eliminating rejected parts and unforeseen downtime.
To profitably machine high-quality parts, many manufacturers follow a similar path, beginning with tool selection and application and then solving any problems that arise in a reactive way.
However, research suggests that manufacturers should examine the entire machining process before cutting begins, focusing on eliminating rejected parts and unforeseen downtime.
Manufacturers should take a three-step approach to setting up a machining process:
- Establish a stable, reliable process.
- Analyze production economics to balance production rates and manufacturing costs.
- Carefully select cutting conditions and tools to optimize the machining process.
Consistent product quality is a goal shared by all manufacturers. If machined parts don’t achieve the level of quality specified by the customer, it doesn’t matter how many, how fast or how cost-effectively the parts are machined.
For example, focusing only on maximum output by exclusively pursuing lower cycle times can damage the reliability of a metalworking operation. When an operation constantly runs at the limits of performance, exceeding them results in scrap and lost time and money. Part output must be balanced with machining parameters that provide a secure machining process.
On the other hand, the cause of rejected parts may be a separate issue from the production-related elements of machining. In one instance, a manufacturer of aerospace components didn’t fully deburr a family of parts, making them unacceptable to the customer. Because deburring required manual work that added 20 percent to the cost of the parts, production output became a secondary issue behind the need to find a way to eliminate burr formation.
In addition, minimizing downtime means maximizing the use of manufacturing resources. Traditionally when a problem halts production, a shop begins searching for a solution. A better approach than reacting to a negative situation is to create a proactive plan that recognizes key targets of the operation and steers the process toward them from the beginning.
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