29-01-17 Summary for mould processes efficency
As shop floor Moulding technical processes evolve, so does its procedures and ways to increase performance, hence efficiency, to get revenue and better market position.
In a simplified view we can come across to many challenges (variables) inside the full mould manufacturing process. The presented ones came mostly from metal mechanics (as serial part manufacturing), but one can extract and learn thoroughly from that experience.
In the average job shops, machines require constant monitoring, engineers scramble to keep up with demand, and equipment is not fully utilized.
Better CAM programming strategies and machining techniques will make your job shop more productive and run more smoothly.
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Preparation |
CAD 2 MANUFACTURING |
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• Faulty file translations |
• Work with any file format |
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• Constant design changes from the customer resulting in manual program updates |
• Agility in handling customer changes |
| • Lost productive machine time |
• Model and program in the same environment |
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• Parts of workflow can be done in parallel |
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• Work is sequential with a linear workflow |
• Better tool room knowledge (existing cutting tools, machining capacity) |
SETUP
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• Manual setups |
OPTIMIZED SETUP |
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• Inefficient fixturing or one part fixturing |
• Creative fixturing |
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• Uncertainty about best and most efficient machine to use for the job |
•Ability to set up several projects at one time |
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• Know with certainty when to use the right machine & tool for the part |
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• Accessory and cutting tool management storage random location |
• Know with certainty what and where the assigned accessories and cutting tools are. |
MACHINING
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• Lower feed rates resulting in longer cycle and cutting times |
MAXIMIZATION |
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• Faster feed rates from constant engagement |
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• Not using cutting tool to full capacity |
• Maximized tool life (tool vs geometry vs material) |
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• Confidence in unattended machining |
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• Excessive air movements |
• Higher quality machining resulting in lower scrap rate |
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• Random Information sheet |
• Standard info for several persons/ shifts (job at a known point) |
INSPECTION
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• Time-consuming manual inspection |
CONSISTENT RESULTS |
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• On-machine probing to verify in-process operations |
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• Post-machining finish work often required |
• Higher quality finish |
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• Shorter manual inspection time |
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• Lower finish quality due to compromises |
• Final check up as standard procedure. |
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