Showing posts with label Cost reduction - technology. Show all posts
Showing posts with label Cost reduction - technology. Show all posts

Monday, July 21, 2025

Productivity Improvement - “Industry 4.0, Leapfrog Opportunity for India” - Productivity Week Theme - India 2018



Industrial Engineering is Improvement Engineering. - Narayana Rao.





                                 IE Observing and Noting the Work Being Done on CNC Lathe






-------------------------------

12 to 18, February 2018 is the Productivity Week in India


“Industry 4.0, Leapfrog Opportunity for India” - Productivity Week Theme - India 2018

National Productivity Council - India - Theme Paper

http://www.npcindia.gov.in/wp-content/uploads/2017/07/Theme-Paper-2017-18.pdf

What is Industry 4.0?


The Fourth Industrial Revolution is using data captured by sensors in products and manufacturing equipment, analyzing to get information and using that information to automatically start and stop machines that include robots to d manufacturing and maintenance operations. This will improve productivity, quality and maintainablity. It is a revolution in manufacturing technologies brought about by international networking between things that facilitate communication and action. So the productivity of man can further go up due more efficient and effective connected machine net work and standard of living of the people is expected to go up substantially. Some countries are in the forefront in this revolution already with number of patents and factories that implemented these technologies.

NPC is driving Industry 4.0 in India through the productivity week celebration of 2018

The Fourth Industrial Revolution will result in the “Smart Factory”, which is characterized by versatility (flexibility and mass customization), resource efficiency, high incomes and  human friendly work environment (less discomfort to human operators) and digital integration with business partners.


Smart manufacturing - Benefits:
• Additional Revenue (Top line improvement)
• Lower Cost (Bottom line improvement)  through:

• Enabling Industrial Companies to redesign and optimize customer relationship.
• Enabling Industrial Companies to redesign and optimize the production process
• Visibility of  the status of all aspects of production system in real time
• By improving logistics processes and making them also  leaner
• Reduced inventories
• Maintenance processes standardization and optimization
• 100% traceability

Different  technologies of Industry  4.0 are available to choose and implement  based on the relevance, cost-effectiveness, and impact on productivity enhancement based on the current systems of organizations

• Additive Manufacturing – 3D Printing
• Sensors
• Robots (auto + co-bots)
• Simulation
• Augmented reality
• Cloud Computing
• Big Data and Analytics
• Industrial Internet
• Horizontal and vertical integration

Cyber security is being strengthened to protect the information of the industrial companies that is stored and transmitted in the digital data stores (warehouses) and communication networks.

Productivity Science - Productivity Engineering - Productivity Management Framework in Productivity Improvement Through Industry 4.0



Productivity Science

Technology Change and Productivity

Changes in technology are the only source of permanent increases in productivity, but a number of transient factors can affect both true and "measured" productivity. For example, workers may work harder during periods of high demand and firms may use their capital assets more intensively by running factories for extra shifts; both factors can lead measured productivity to be too high relative to actual technological progress. Similarly, during periods of high demand, productivity can also rise due to increasing returns to scale. But,  the effect of transient factors is not permanent.
http://www.nber.org/digest/oct01/w8359.html

So permanent productivity improvement is brought about by engineering changes, procedure changes in service processes as well as management processes.

Industry 4.0 is offering number of new technologies and there technologies are to be incorporated into manufacturing and other engineering and business processes to increase effetiveness and efficiency. Management of incorporating the new technology and operating the redesigned facilities are also important to realize the benefits of Industry 4.0. Hence productivity engineering and productivity management also are involved.

Important Papers on IoT and Productivity

THE COMING PRODUCTIVITY BOOM: 

Transforming the Physical Economy with Information
http://www.techceocouncil.org/clientuploads/reports/TCC%20Productivity%20Boom%20FINAL.pdf



Embracing Industry 4.0 - Surviving and Growing in the New Manufacturing Environment

Industry 4.0: The Future of Productivity and Growth in Manufacturing Industries - Embracing Industry 4.0—and Rediscovering Growth

BCG View

Nine Technologies Transforming Industrial Production 


BIG DATA AND ANALYTICS

AUTONOMOUS ROBOTS

SIMULATION

HORIZONTAL AND VERTICAL SYSTEM INTEGRATION

THE INDUSTRIAL INTERNET OF THINGS

CYBERSECURITY

THE CLOUD

ADDITIVE MANUFACTURING

AUGMENTED REALITY

https://www.bcg.com/en-in/capabilities/operations/embracing-industry-4.0-rediscovering-growth.aspx


More Details on Technologies

BIG DATA AND ANALYTICS

AUTONOMOUS ROBOTS

SIMULATION

HORIZONTAL AND VERTICAL SYSTEM INTEGRATION

THE INDUSTRIAL INTERNET OF THINGS

CYBERSECURITY

THE CLOUD

ADDITIVE MANUFACTURING

AUGMENTED REALITY

ARTIFICIAL INTELLIGENCE



Dec 10, 2017.
Top 100 Business Use Cases of Artificial Intelligence
https://medium.com/@utpal_bob/top-100-business-use-cases-of-artificial-intelligence-by-utpal-chakraborty-721a495ebed4

Important Themes of Industry 4.0


The Factory of the Future
Time to Accelerate in the Race Toward Industry 4.0
Man and Machine in Industry 4.0
Industry 4.0: The Future of Productivity and Growth in Manufacturing Industries

https://www.bcg.com/en-in/capabilities/operations/embracing-industry-4.0-rediscovering-growth.aspx


https://www.manufacturingtomorrow.com/tag/industry-40

Data Analytics Period in Productivity Improvement - Productivity Engineering and Management

http://nraoiekc.blogspot.com/2017/06/data-analytics-period-in-productivity.html



Digital Transformation at Daimler Benz - 2015

http://nraoiekc.blogspot.com/2016/04/digital-transformation-at-daimler-benz.html


Industry 4.0 in India - Status, Implementations, Consultants and Product Manufacturers and Sellers

2017

Industry 4.0: Towards Smart Manufacturing

May 2017
http://businessworld.in/article/Industry-4-0-Towards-Smart-Manufacturing/26-05-2017-118968/


 “The fourth industrial revolution, agricultural and rural innovation, and implications for public policy and investments: A case of India”  Agricultural Economics, November 2017 issue.
http://ideasforindia.in/article.aspx?article=How-new-technologies-can-raise-farm-productivity


Prepare for a worldwide digital transformation

Geoff Maslen01 December 2017
University World News Issue No:485

Mobility, cloud computing, the Internet of Things, artificial intelligence and big data analytics are among the most important technologies in the digital economy today, says the OECD’s latest report on international science, technology and industry.
http://www.universityworldnews.com/article.php?story=20171201150237763


Onset of Industry 4.0 and print industry’s next frontier


By Puneet Datta,
18 August 2017
http://www.printweek.in/features/onset-industry-print-industry-frontier-25829


New Technology to Enhance Productivity for Manufacturing

By Ruth Morris - June 11, 2017
IoT productivity improvement training to small businesses in Massachusetts, USA
http://www.masstlc.org/new-technology-to-enhance-productivity-for-manufacturing/


Journey of Andhra Pradesh Towards Industry 4.0

January 11, 2017
http://www.electronicsb2b.com/headlines/tale-state-journey-towards-industry-4-0/

India's Readiness for Industry 4.0
A Report by Grant Thorton and CII


How to Leapfrog Effectively


https://www.weforum.org/agenda/2018/01/how-businesses-can-win-at-leapfrog




More Links

Kranti - Knowledge India
https://books.google.co.in/books?id=Ui82DwAAQBAJ&printsec=frontcover#v=onepage&q&f=false

https://www.enterprisetv.com.my/the-make-in-india-initiative-and-the-role-of-industry-4-0/

http://smartmanufacturingindia.com/

https://www.weforum.org/agenda/2017/10/kranti-nation-india-and-the-fourth-industrial-revolution/

https://blogs.timesofindia.indiatimes.com/Arrackistan/kranti-nation-why-india-should-not-miss-the-4th-industrial-revolution/

http://www.covacsis.com/benefits.php

IoT Show India - 2018


7th to 9th February, 2018
KTPO TRADE CENTER, WHITEFIELD INDUSTRIAL AREA BANGALORE

You can visit exhibitor from the following  categories and learn more about IoT and Industry 4.0

• Chipset manufacturers
• Network technologies and Wireless solutions
• Robotics and drones
• IoT Security
• IoT OEMs
• Semiconductors/ hardware
• Sensors
• Service Platform/ solution provider
• Software development provider
• Carrier service provider
• Standards/ Protocols/ Certification and testing providers

https://www.iotshow.in/iotshow/

Companies to Contact for Helping you in having IoT Initiatives in India

3Q Wire & Cable Co., Ltd
A G Enterprises
AADI International
Aimtron Electronics Pvt Ltd

Akrivia Automation Private Limited
Established in 2015, Akrivia is an IT, Automation and customized IoT solution provider. We work with verticals such as electrical equipment, smart factories, intelligent buildings, smart cities and Industrial Automation.
http://www.akrivia.in/


Anand Enterprises
Anritsu India Pvt Ltd
ANSYS Software Pvt Ltd
Applied RealTech Systems Pvt. Ltd.
AqTronics Technologies Pvt. Ltd
Array Networks
Ascent Circuits Pvt. Ltd.
Ashlyn Chemunnoor Instruments Pvt.Ltd.
AxesTrack Software Solutions Pvt. Ltd.
Axiom Energy Conversion P Ltd.
Bharat Head Hunters Pvt. Ltd.
Carl Zeiss India (Bangalore) Pvt. Ltd.
Changzhou Shunye Electronic Co. Ltd.
Circuit Systems India Ltd
Circuitects Electronics Solution Pvt. ltd.
Cirkit Electro Components P Ltd (D)
Clean Energy LOGAN INNOVATIONS Pvt Ltd
CloudThat Technologies Pvt. Ltd.
Component Masters
Crevavi Technologies Pvt Ltd
CSA India PVT LTD
CTC Technologies
cyrrup enterprises
CYTECH GLOBAL PTE LTD
DDS International
Delta India Electronics Pvt. Ltd.
Digi-Key Electronics
Dongguan Tongke Electronic Co., Ltd.
Drive Technologies (D)
E Control Devices
Elcina Electronic Industries Association of India
Electroconnect Systems
Electronic Relays India Pvt Ltd
Element14 India Pvt Ltd.
EmbDes Technologies Pvt. Ltd
EMST Marketing Pvt Ltd
Energy Saving India
ESSCI (Electronics Sector Skills Council of India)
FLIR Systems India Pvt. Ltd.
Forward Electronics Technologies
Fraunhofer
Fusion Power Systems (D)
G&g Universal Private Limited
G.T. Enterprises (D)
Gala Electronics (D)
Galore Systems
Geosensors
Good Will Instrument Co. Ltd
Greenconn Technology (Shenzhen) Co., Ltd
GT Magnetics Pvt. Ltd.
GuangDong Kexin Electronic Co.,Ltd
Guangdong Shunde Xu Hai Electronic Co., Ltd.
Hangzhou Chuanlian Electronics Co.,Ltd.
HARIHI OHM ELECTRONICS
HK Wentworth (India) Pvt Ltd
HyperThink Systems Pvt. Ltd.
Ignitarium Technology Solutions Pvt Ltd
INCHANGE SEMICONDUCTOR COMPANY LIMITED
Indus Technologies
Infiction Labs
infiswift
Innovative Resource LTD
Intel technology India pvt Ltd
IntuIT Things
Invendis Technologies India Pvt Ltd
iTECS Communication Pvt ltd.
iValue InfoSolutions Pvt Ltd.
Jharkhand Government
Jigsaw Academy
JSK Innovative Technology Pvt Ltd
Kadel Labs
Karandikar Laboratories
Karsan Technologies
KCG College of Technology
Keysight Technologies India Pvt. Ltd.
KIDOBOTIKZ
Kwality Photonics P Ltd
Liveon Technolabs
M.P State Electronics Corporation Ltd
Mahaveer Sales
Martin Electronic Devices & Instruments
MARVEL GEOSPATIAL SOLUTIONS Pvt. Ltd.
MAXIM INTEGRATED
Mectronics Marketing Services
Melux Control Gears Pvt Ltd
Messung Global Connect
Metro Electronics Products
MG Automation Technologies
MICRON
Microsoft Corporation (I) Pvt. Ltd.
Mobiloitte Technologies (I) Pvt. Ltd.
Mobiveil Technologies India Pvt Ltd
Module 143
Mouser Electronics (India) Private Limited
Moxa India Industrial Networking Pvt. Ltd.
National Small Industries Corporation Ltd. (NSIC)
NEE VEE Communication Technologies Pvt Ltd
NetSim (Tetcos)
Ningbo EHOME Electronic Co.,Ltd
NSIC Ambala
NSIC Noida
O/E/N India Limited
Peach Technovations Pvt Ltd
Phytec Embedded Pvt Ltd
PIE ELECTRONICS
Precision Tech Enterprises
Pulsar Enterprises Pvt Ltd
Qingdao Ainuo Intelligent Instrument Co Ltd.
Qualcomm India Pvt Ltd
Quasar Enterprises
Quectel Wireless Solutions Co Ltd
Rajguru Electronics
Redpine
Robotron solutions
ROHM Semiconductor India Pvt. Ltd.,
Royal Appliances
Royal Elegance Technologies Pvt Ltd
RS Components & Controls (I) Ltd
Schenker India Pvt. Ltd.
Scientech Technologies Pvt Ltd
SECO SRL
Sensegiz Technologies Private Limited
Sensinova
Sensor Embedded & Android RoBo (P) Ltd

Sensors India
http://sensors-india.com/about-us/

We are Automation components distributor and Systems Integrator all over India.



Our organization is aware of top automation applications with an experience of over 25 years in the field of Automation and System Integration.. We have successfully created a base of Automation technicians providing automation solutions all over India like Greater Noida, Uttar Pradesh, Manesar, Haryana, Chakan, Ranjangaon, Talegaon, Pune, Aurangabad, Nashik Maharashtra, Hospet, Karnataka, Sriperumbudur, Tirupur, Tamil Nadu.

www.Sensors-India.com is Stockist, Wholesaler, Importer, Trader, Distributor, Imported Products, Integrated Systems, Made in India Products representative and Systems Integrator for a wide range of sensing and control products plus Annual Maintenance Contract (AMC).

Handling automation projects like Systems Integration, Parking Guidance Systems, Security Alarm GSM Alert Systems, AMC projects, Installation and Commissioning, Manufacturing/Processing operations, CCTV and Access Control System, Cabling, Piping installations, PUMP control systems, Water level Management includes Leakage sensing and Centralised monitoring, Lighting automation and energy monitoring and audit SCADA systems



SETU INFOCOM
SFO Technologies P Ltd
SGS India Pvt Ltd
Shanghai Yongming Electronic Co.,Ltd.
Sharang Corporation
Shenzhen Baikal Electronic Materials Co. Ltd.
SHenzhen Jin Hao Yuan Technology.
SIGMA DESIGNS
SINCOM
Smarter Biz Technologies Pvt Ltd
Smile Electronics
Srashta Scientific Systems Pvt Ltd
Static Systems Pvt Ltd
Superior flux & Marketing
System Level Solutions (India) Pvt. Ltd.
Technosphere Labs Pvt. Ltd.
Telangana Government
Testo India Pvt. Ltd.
TEXIN (HONGKONG) ELECTRONICS CO.,LTD
TnC India
Toradex Systems (India) Private Limited
Toshniwal Sensing Devices Private Limited
TUV Rheinland (India) Private Limited
U H Led India Inc
Uchi Embedded Solutions
UM ELECTRONICS CO.,LTD.
UniQtronics Solutions Private Limited
Unisem electronics Pvt Ltd
V5 Semiconductors
Vanmat Technologies Pvt. Ltd
Vision Mechatronics Pvt Ltd
VMware Software India Pvt Limited
Wenzhou M & C Foreign Trade Co., Ltd.
Winday electronic (Dongguan)CO.,LTD
Wisys Technologies
Xiamen Prt Technology Co., Ltd.
XIANGTAI ELECTRONICS(SHENZHEN) CO.,LTD
YMD Electromac Pvt. Ltd.
Yontro Mechatronic Systech
Zeal Manufacturing Co.
Zoho Corporation Pvt Ltd

https://www.iotshow.in/list-of-exhibitors/  (date 16 December 2017)

Kerala State Productivity Council
http://www.kspconline.com/




List of Industry 4.0 Light Houses - WEF - McKinsey - Have You Benchmarked with the Best in Industry 4.0 Implementation?

Updated 21.7.2025,    17 January 2018

2017 -  16, 12, 11 December 2017, 7 December 2017

Wednesday, June 7, 2023

Robots and Cost Reduction

2023

2017

ABB Frosinone - Collaborative Robotics: more products, more work
2017-07-20 - A textbook example of how Industry 4.0 at an ABB plant in Italy has brought greater employment and production.
http://www.abb.com/cawp/seitp202/BF4B589876268CA6C125814F004DEEDC.aspx

What Is the Real Cost of an Industrial Robot Arm?
Ken Thayer
27 April 2017
Labor cost savings due to Robot use is given for many countries in the year 2025.
http://insights.globalspec.com/article/4788/what-is-the-real-cost-of-an-industrial-robot-arm


The Robotmakers – Yesterday, Today and Tomorrow
by Tanya M. Anandan, Contributing Editor
Robotic Industries Association
POSTED 04/28/2017
https://www.robotics.org/content-detail.cfm/Industrial-Robotics-Industry-Insights/The-Robotmakers-Yesterday-Today-and-Tomorrow/content_id/6513

2016

Reduction of Robot Price

The cost to purchase and implement a robotic spot welder has plummeted from $183,000 in 2005 to $132,000 in 2014, with the price forecasted to drop another 22% by 2025, according to Technavio’s lead industrial automation analysts.

In computer electronics manufacturing, it costs $4 per hour to use a robot for a routine assembly task compared to $24 for an average worker. In the US, industrial robots in auto manufacturing are already operating at a cost of $7.25 hourly wage after the cost of the robot is recovered. For example: the Baxter collaborative robot from Rethink Robotics, which works alongside the human workforce on the factory floor, only costs $22,000.
https://www.technavio.com/blog/industrial-robots-united-states-cut-labor-costs-21-2020


At Ford's factory in Cologne, Germany,  collaborative robots, or co-bots are working side by side with 4,000 Ford factory workers.

Automakers are leading the way in the adoption of co-bots, which they say are more cost-effective than industrial robots. The average selling price of a co-bot is close to $30,000, a number expected to drop to $18,500 by 2020. Automakers prefer the flexibility that comes with co-bots, which can work without safety cages and therefore can be rolled around to different parts of the factory.
https://www.cnbc.com/2016/10/31/ford-uses-co-bots-and-factory-workers-at-its-cologne-fiesta-plant.html


2015
Robotics systems are becoming an economically viable alternative to human labor in more and more industries. A human welder today earns around $25 per hour (including benefits), while the equivalent operating cost per hour for a robot is around $8 when installation, maintenance, and the operating costs of all hardware, software, and peripherals are amortized over a five-year depreciation period. In 15 years (by 2030), that gap will widen even more dramatically. The operating cost per hour for a robot doing similar welding tasks could plunge to as little as $2 when improvements in its performance are factored in.
https://www.bcgperspectives.com/content/articles/lean-manufacturing-innovation-robots-redefine-competitiveness/




Justifying the Cost of a Robotic Welding System
http://www.lincolnelectric.com/assets/US/EN/literature/mc04179.pdf
Robots in packaging: It’s all about cost savings

2008

Robotics and Energy Cost Reduction
by Bennett Brumson , Contributing Editor
Robotic Industries Association
Posted 08/02/2006
http://www.robotics.org/content-detail.cfm/Industrial-Robotics-Featured-Articles/Robotics-and-Energy-Cost-Reduction/content_id/1047

Robotic systems employed in decontamination and decommissioning (D&D) applications offer potential benefits in terms of decreased personnel radiation exposure and decreased personnel costs. Robotic systems seem particularly suited to the repetitive nature of the gaseous diffusion plant (GDP) process building designs.
Google Search Link for Robots Cost Reduction


Updated 5 August 2017, 30 Jan 2014

Wednesday, April 27, 2022

CNC Machine - Setup Time Reduction - Bibliography - Case Studies



ADVANCED MANUFACTURING - AUTOMATE CNC SETUP. MAXIMIZE PRODUCTIVITY.

Optimize your CNC milling machine usage with automated setup and on-machine verification. Adopt a ‘right-first-time’ approach to manufacturing parts that significantly reduces machine setup time, saves on potential re-work, and maximizes your productivity.








2021
Standardized Workholding Saves Shop Hours of Setup Time
5th Axis’ workholding solutions have enabled Will-Mor Manufacturing to achieve vastly better repeatability and stability, cutting setup time and even whole setups.
7/7/2021

2019
Application of the single-minute exchange of die system to the CNC sector of a shoe mold company
Rodrigo Borges Ribeiro et al.
Cogent Engineering
Volume 6, 2019 - Issue 1
https://www.tandfonline.com/doi/full/10.1080/23311916.2019.1606376


2014

In a machine shop with  45 employees, a four-axis CNC lathe was used to make large aerospace parts that were shipped on a monthly basis.  The change over and setup for one of the routine parts was taking just under 16 hours (two shifts).  Since the set up took so long, the company was typically making 3-5 months worth of parts at a time and store them  and then ship them out of inventory.  Occasionally customers would make changes to parts, which meant that the parts that had already been made were no longer what the customer wanted.  Also as the lathe was making parts of a batch of 3-5 months, the lathe was not availabe for other current, more pressing demands.

Six employees spent five days studying the process and reducing the changeover and setup time. A target of 50% reduction was chosen (Shigeo Shingo says, separating external and internal activities will give the size of saving).

At the end of the five day event, one changeover and set up had been done in 7 hours.  Additional improvements  would take three more weeks to implement setup will take  5 to 5 1/2 hours.

Savings:  The company has four of these lathes and by applying what had been learned to all four lathes, sixty four hours per week could now be used for making parts.  With changeovers taking less than one shift, the company decided that they would make parts for that month requirement only , so the cost of parts being held in storage was eliminated.
http://www.systemsquality.com/ id26.html (Site not available now)


Setup Time Reduction on CNC Shaper  2011 article
http://www.interscience.in/IJMIE_Vol1Iss1/paper9.pdf

MS disseration on CNC Machine Setup Time Reduction 2009 - Haiqing Guo - MIT
http://dspace.mit.edu/bitstream/handle/1721.1/55215/611148027.pdf?...1



CNC Programming Handbook: A Comprehensive Guide to Practical CNC Programming
Peter Smid
Industrial Press Inc., 2003 - Computers - 508 pages

Extraordinarily comprehensive, this popular and authoritative reference covers just about every possible subject a typical CNC programmer may encounter on a daily basis. Fully indexed to help the user quickly locate topics of interest, this "industrial strength" handbook presents most common programming subjects in great depth and is equally applicable to both CNC milling and CNC turning operations. Many advanced subjects are also covered, thus making this an unusually comprehensive reference for machinists, programmers, engineers, and supervisors. Filled with over one thousand illustrations, tables, formulas, tips, shortcuts, and practical examples, this widely respected publication is structured in a logical order that is readily adaptable to virtually all levels of CNC training, from the basic to the advanced.

CNC Programming Handbook has just become more valuable than ever! A new CD-ROM, packed with actual problem-solving projects and enhancing the material presented in the book, is included for the first time. Users will find programming projects and exercises for most chapters, special programming and machining projects, solutions to problems, and numerous reference files useful in CNC programming, as well as several utilities. With the majority of files in Adobe PDF, instructors will be able to quickly and easily print and distribute any of the projects, exercises, and references to their classes. Meanwhile, students and professionals will find this CD an effective self-study aid that allows them to enhance their understanding of the subject one topic at a time. Presents complete information on various programming techniques, from the basic areas to dozens of advanced concepts. Includes more than 1,000 illustrations, tables, formulas, tips, shortcuts and real-world examples. Offers unparalleled reference material useful for skills training at all levels of CNC. Presents an encyclopedic, logically organized approach to CNC programming, allowing the reader to look up a subject of interest only. Uses cross references throughout to guide the reader to the proper answer or solution to a problem.
http://books.google.co.in/books?id=JNnQ8r5merMC

Understanding CNC Machines, Setup and Operation
Richard N. Jackson
Clinton Gilkie
http://books.google.co.in/books?id=GuBSl1NHSh4C

Organizational Skills Cut Machine Setup Time
http://www.mmsonline.com/columns/organizational-skills-cut-machine-setup-time

CNC Machining Fundamentals
http://www.mfgaa.com/fundamentals.html

Magnetic vice
http://www.industrydepot.com/ProductivityNews0113.htm

Zero point mounting kits for setup time reduction
http://clrh.com/swiftsure/starkkits.html

Set up Reduction – A perfect way for productivity improvement of computer numerical control (CNC) set
up in manufacturing company
by - Patel Chintan Kumar, Department of Mechanical Engineering, C. K. Pithawala College of Engineering and Technology, Dumas Road, Surat-395007, Gujarat, India.
17 August, 2012
http://academicjournals.org/article/article1382090861_Kumar.pdf

Benefits of Presetting systems - CNC Setup
http://www.pomlearning.org/reno/fullpapers/020-0030%20Statement%20of%20Losses.pdf


How to reduce setup time in CNC tool grinding?
http://rollomaticusa.wordpress.com/2013/01/08/12/


Spencer Tool Setter with CNC software program that assists your operator in accurately measuring and recording tool lengths into the CNC memory.
http://www.stevespencermachinery.com/?page_id=46


Setup Reduction For CNC Machining & Turning Centers CD Rom Course $239.00
http://stepper3.com/index.php?main_page=product_info&products_id=135

Vacuum Clamping technology for cnc tools
http://www.protech.hu/schmalz/CNC_Vakuum.pdf

CNC Tool Cart
http://blog.5ssupply.com/2013/08/19/one-simple-solution-to-reduce-waste-of-searching-for-cnc-machine-tooling/

Increasing CNC Production throughput with Tool Presetting with a YouTube video of 14 minutes embedded
2012
http://nextgentooling.com/profiles/blogs/increasing-cnc-production-throughput-with-tool-presetting

Workstops and Gang Tool Holders for CNC
http://toolpal.com/cnc-setup-tools/


CNC Machine Productivity Series Articles

http://www.cnccookbook.com/CCCNCMachiningManufacturing.htm

CNC Machine Productivity - Basic article
http://www.cnccookbook.com/CCCNCMachineShopProductivity.htm

Whether to focus on saving Machine Cycle Time or Machine Setup Time to improve Shop Productivity?
http://www.cnccookbook.com/CCCNCCycleTimeSetupTime.htm

Top Shops - What do they do differently?
http://blog.cnccookbook.com/2013/07/29/what-do-the-top-shops-do-that-makes-them-special/

Are you using High Speed Machining? - Above 18,000 rpm
http://www.cnccookbook.com/CCCNCMillFeedsSpeedsHighSpeedMachining.htm

By incorporating new CNC programming software to make full use of its new five-axis machining capabilities, Bob Lewis Machine Co. has reduced setups and programming time.
Case Study From: 4/19/2013 Modern Machine Shop
http://www.mmsonline.com/articles/cnc-programming-software-maximizes-five-axis-capability


Cycle Time Reduction for Bearing House Assembly
K. Saran Kumar Reddy, T. Panneer Selvam and R. Venkatraman
Published: June 30, 2012
http://scialert.net/fulltext/?doi=jas.2012.992.998&org=11

Mill/Turn centers or Multitasking machines.
http://www.sme.org/MEMagazine/Article.aspx?id=67675&taxid=1418

Drastic Reduction in piece times with high performance cnc machining - 2008
http://www.index-werke.de/mediadata/tnx-0199e.pdf


To be updated 27.4.2022,  11.3.2022, 6 December 2019,   7 April 2016

26.3.2014

Wednesday, January 12, 2022

Cost Reduction - Concept Papers, Cases, Reports and News


Books - Cost Reduction - Cost Management

When Lean Enterprises Collide: Competing Through Confrontation

Robin Cooper
Harvard Business Press, 1995 - Business & Economics - 379 pages

When Lean Enterprises Collide reveals a new theory of competition in which lean manufacturers  create the most innovative product at the lowest price. These firms engage in a game of constant and lightning-fast leapfrogging in pursuit of transitory gains. This is the confrontation strategy, and it will shape the competitive landscape for lean enterprises.

Cooper shows that the key to success in such an environment is the careful balance of cost, quality, and functionality - the survival triplet - in which cost is the critical element. He describes eight innovative cost management techniques - including target costing and value engineering - that have emerged in Japanese firms to manage costs across the value chain. Leading manufacturers must use aggressive cost management along with TQM and time-to-market to develop products with the appropriate mix of quality, cost, and functionality to satisfy the customer.

Evidence of this relentless confrontation strategy and the hidden role of cost management within it emerged during Cooper's five-year study of the management systems inside twenty Japanese companies, including Olympus, Nissan, Citizen, and Komatsu.




Concept Papers


CFD for Productivity in Design
http://nraoiekc.blogspot.com/2012/08/cfd-software-being-promoted-as-cost.html

Robust Design Optimization for Productivity in Design Departments
http://nraoiekc.blogspot.com/2012/08/robust-design-productivity-during.html

Riding the Storm in 2012 - How to make cost reduction possible? Deloitte White paper
http://deloitteblog.co.za.www102.cpt1.host-h.net/wp-content/uploads/2012/08/How-to-make-enterprise-cost-management-sustainable.pdf
Easy efficiency opportunities have dried up. But still cost reduction is required. This means more strategic, agrresive cost and performance initiatives have to be taken up by companies.

Sustained Cost Reduction - Bain & Co.
http://www.bain.com/publications/articles/sustained-cost-transformation.aspx




Sustained Cost Transformation - Bain
http://www.bain.com/consulting-services/performance-improvement/sustained-cost-transformations.aspx

Supply Chain Cost Reduction




Supply Chain Development for the Lean Enterprise: Interorganizational Cost Management
1st Edition
By Robin Cooper, Regine Slagmulder
Copyright Year 1999
ISBN 9781563272189
Published June 18, 1999 by Productivity Press
544 Pages
https://www.routledge.com/Supply-Chain-Development-for-the-Lean-Enterprise-Interorganizational-Cost/Cooper-Slagmulder/p/book/9781563272189

Top Consultants in Cost Reduction


Strategic Cost Reduction: Services Overview - Accenture
http://www.accenture.com/us-en/Pages/service-strategic-cost-reduction-services.aspx

Sustained Cost Transformation - Bain
http://www.bain.com/consulting-services/performance-improvement/sustained-cost-transformations.aspx

Sustainable Cost Reduction - Deloitte
http://www2.deloitte.com/us/en/pages/operations/solutions/about-our-strategic-cost-reduction-services.html


Cost Management and Cost Reduction - KPMG
https://www.kpmg.com/ro/en/services/advisory/performance-technology/business-performance-services/cost-management-cost-reduction/pages/default.aspx

Design to Value - McKinsey
http://www.mckinsey.com/client_service/operations/expertise/product_development/design-to-value

Sustainable Cost Reduction - PWC
http://www.pwc.com/us/en/industry/entertainment-media/sustainable-cost-reduction.jhtml







Scope and Challenge Papers


2012

Achieving Sustainable Cost Reduction in Investment Banks - Accenture
http://www.accenture.com/us-en/blogs/accenture-core-trading-blog/archive/2012/07/02/achieving-sustainable-cost-reduction.aspx

For Photovotaics cost reduction is a priority
http://www.pv-tech.org/guest_blog/high_efficiency_grabs_the_headlines_but_cost_reduction_remains_the_priority

IT Cost Reduction - CIOs are using New Technologies
http://www.accenture.com/us-en/Pages/insight-it-cost-reductions-new-technologies.aspx



Case Studies and News


August 2012

Cost Reduction Opportunity in Imaging Systems in Companies

The process of optimizing the imaging and output infrastructure unnecessarily high costs and underutilized assets. IDC Research studied nine large enterprises in the United States, Europe, and Asia and found the majority of organizations studied reported major problems related to overall cost awareness of their imaging hardware, their ability to assess device utilization, and high costs of maintaining an often aged and out-of-date fleet of printers, copiers, and multifunction devices. Based on the experiences of these nine companies and other research, IDC published a white paper that looks at the unnecessary costs and inefficiencies that typically exist within these resources and the significant opportunities to achieve cost savings, boost employee productivity, and speed up core business processes from tighter integration between the document advances of hardcopy devices and business process workflows.
http://ievarunmitra.blogspot.in/2012/08/cutting-costs-and-maximizing-return-on.html

May 2011

Lean Processes Trim $1.3M in Costs From ORs at Michigan's Oakwood Annapolis Hospital
http://www.beckershospitalreview.com/or-efficiencies/lean-processes-trim-13m-in-costs-from-ors-at-michigans-oakwood-annapolis-hospital.html

DuPont™ Surlyn® as a Seal Layer Enables Increased Productivity During Filling of Resealable Tubular Bags
http://www2.dupont.com/food-beverage/en-us/fb/press-release/surlyn-seal-productivity.html


Updated  12.1.2022,  6 March 2015, 21 Feb 2013

Saturday, February 20, 2021

Machine Shop Cost Reduction News up to 2014 - Metal Working - Cost Reduction Opportunities

Machining Time Reduction - Productivity Improvement News


2014
Four Cost-Cutting Tips for CNC Machining
Daniel Clark
JUL 31, 2014
https://www.americanmachinist.com/shop-operations/article/21898592/four-costcutting-tips-for-cnc-machining


ORIGINAL ARTICLE
Published: 29 June 2014
Development of a smart machining system using self-optimizing control
Hong-Seok Park & Ngoc-Hien Tran 

2013

Productivity Technology in Metal Cutting - 2013

Manufacturing Systems Conference 2013 Papers - Bibliography

11. A study on the heating process for forging of an automotive
crankshaft in terms of energy efficiency
http://cms2013.ceni.pt/wp-content/uploads/2013/05/11_paper.pdf

42. An approach for a cloud-based machine tool control
http://cms2013.ceni.pt/wp-content/uploads/2013/05/42_paper.pdf

49. A Study of Automatic Determination of Cutting Conditions to
Minimize Machining Cost
http://cms2013.ceni.pt/wp-content/uploads/2013/05/49_paper.pdf

57. Beyond Lean and Six Sigma; Cross-Collaborative Improvement of  Tolerances and Process Variations - A Case Study
http://cms2013.ceni.pt/wp-content/uploads/2013/05/57_paper.pdf

62. Current State of Standardized Work in Automotive Industry in
Sweden
http://cms2013.ceni.pt/wp-content/uploads/2013/05/62_paper.pdf

64. Manufacturing of Twist-Free Surfaces by Hard Turning
http://cms2013.ceni.pt/wp-content/uploads/2013/05/64_paper.pdf


2012



30 November 2012
Complementarity and Cost Reduction - 1997 paper on Automobile Industry

Cost Effective Machining of Brass, Copper and Its Alloys

Cost Reduction of a Chassis and Cover by switching to Die Casting - Alexander Machine and Tool Company Cases - Cost reduction to $210 per piece frm $300

Emerging Titanium Cost Reduction Technologies

Impression Die Casting Projects - Cost Reduction Achievements - There is crank shaft case also.

Metal Injection Molding - Cost Reduction opportunities for small components with more than 10,000 parts per month and above

Ready for Six Sigma - 2006

Reduction in machining cost of crank shaft die by using a different tool

Setup Time Reduction in Machine Shop


Taking the pain out of  Machining ISO P25 Grade of Steel 
Multicapable insert tackles one of the toughest ISO classified turning areas.


JAN 26, 2006

2004
Richards Industries in Cincinnati, Ohio, - setup reduction
In January 2002, average setup time of CNC machines was 50 minutes. In two years, it was brought down to  average of 27 minutes.  The goal is 20 minutes, by the end of this year. The machine shop has  CNC lathes and mills, about 30 machines in all. In 2001, Richards Industries invited productivity consultants from TechSolve,  a Cincinnati-based firm to help them.
"setup reduction events" have four steps:

Document the current changeover.
Determine what setup steps can be done while the machine is still running.
Streamline setup steps that must be done while the machine is not running.
Put the basics in place for workplace organization and visual control.

The company set out to apply this process systematically, one machine at a time, starting with those machines that had the longest setups. Each "setup reduction event" took about a week. The first was held in February 2002.

As part of the exercise, an efficient workplace was created which has tools, parts etc. that are required in properly place positions so that there is no time waste in locating them.  

Shell Molding Process produces cost savings

Single piece design instead of 5 items - Forging

The Cost of Machine Tool Ownership

Tips on designing for cost effective machines parts

Use  Cold forming in place of machine - Reduce cost

Use continuous casting instead of machining

Use hard turning instead of grinding - Feb 2003


5-axis machining will reduce fixture costs and setup costs

Latest Trends in Machining - Full Book - Drishtikon Book


Machining cost reduction - Google Search Results

Operating A CNC Powered Machine Shop: Roadmap for Efficiency
http://home.earthlink.net/~cadcamcnc/data/Operating%20A%20CNC%20Powered%20Machine%20Shop.pdf


9/1/2001 
Boosting Multi-Spindle Productivity
Here's a look at some of the ways Delta Faucet is taking advantage of off-the-shelf technology to improve multi-spindle screw machining productivity.

















Updated on 19 August 2020
30 November 2012

Friday, January 1, 2021

2019 Machine Shop Engineering & Technology - Productivity Improvement and Cost Reduction News





machine shop cost reduction



How To Reduce The Cost Of Machined Parts
Mar 24, 2019 - Most shops will have a minimum setup/programming fee to machine a part, and that cost will not change whether the order is for 5pc or 5,000. Though machining ...
https://randrmanufacturing.com/blog/how-to-reduce-the-cost-of-machined-parts/

Eight Simple Ways to Reduce Hidden Tooling Costs
Mar 19, 2019 - Tweaking how cutting tools, inserts, and tool holders are selected and ... Delivering optimal productivity from the shop floor is an ongoing quest for plant managers. One way to achieve that is to discover the hidden machine tooling costs that ...
https://www.americanmachinist.com/cutting-tools/article/21903014/eight-simple-ways-to-reduce-hidden-tooling-costs

How to Reduce CNC Machining Costs
Feb 6, 2019 - Here are tips to help you design more cost-effective machined parts. Adding radii and reliefs to corners reduces machining costs. Here's an example of adding ...
https://www.protolabs.com/resources/design-tips/how-to-reduce-cnc-machining-costs/

11 Cost saving & reduction ideas for manufacturing companies
Mar 1, 2019 - Check your labor costs on regular basis. Optimize the use of labor by balancing man-machine activities. Consider versatile multitasking employees.
https://www.smartteh.eu/en/blog/cost-saving-ideas-manufacturing

Machining Case Studies ... - Rugo Machine Shop Services
Jun 20, 2019 - There was also a target for a 10% cost reduction in order to maintain competitive ... RMSS reduced the cost to manufacture the parts by reducing machining time.
https://rugomachineshop.com/rmss-machining-case-studies/


Ideas for Cost-Reduction in Manufacturing | Chron.coms
mallbusiness.chron.com › ... › Employee Training
Mar 24, 2019 - Many cost-saving ideas can be implemented. ... Inventory: Occurs when more product is produced than the market demands, requiring resources to store it until it is ... By investing in efficient manufacturing machines and tools, you can reduce ...

Manufacturing cost estimation for machined parts based on ...
www.researchgate.net › publication › 225818382_Man...
Nov 15, 2019 - Machining cost is proportional to machining time, which includes operational time and non-operational time. Operation time includes rough cutting time and ...

5 Easy Ways to Reduce Your Metal Fabrication Costs - Blog
info.naimormetalfabrication.com › blog › 5-easy-ways-...
Apr 24, 2019 - Reduce the manufacturings costs of your product with custom metal ... If they buy mill-direct, this also means they have the means to buy, ship, store, and ...

Coolant Recycling System Improves Tool Life, Reduces Costs ...
www.mmsonline.com › blog › post › coolant-recycling...
Jan 23, 2019 - This Canadian aerospace manufacturer cut coolant costs by 75 percent by installing a ... With its in-house machining, processing and assembly capabilities, the ... The combined savings from coolant consumption and spent fluid disposal has ...


How to Reduce Manufacturing Scrap and Save Money
www.marlinwire.com › blog › 3-ways-to-reduce-manuf...
Oct 3, 2019 - Learn how Marlin Steel helps our clients reduce costs by eliminating scrap and ... A machine doesn't get a muscle spasm because of a repetitive motion stress ...

Process Planning and Cost Estimation - Vel Tech High Tech
www.velhightech.com › wp-content › uploads › 2019/11
PDF
Nov 20, 2019 - Estimation of machining time for Lathe operations – Estimation of machining time for drilling, ... minimized, a lot of savings can be achieved in cost and effort.


Counterboring | Tooling Overview | eMachineShop
www.emachineshop.com › counterboring
Sep 20, 2019 - General Cost-Saving Machining Tips. Download the FREE guide to learn how to: Design for low-cost manufacturing; Select the most suitable materials and ...


Maximizing spindle idle-time reduction | Cutting Tool ...
www.ctemag.com › news › industry-news › maximizin...
Aug 14, 2019 - Eliminating unnecessary interruptions to production directly affects machining cycle times, costs to complete each part from start-to-finish and, by extension, the ...

Part2b | Machines love it
part2b.com
Jul 10, 2019 - Competitive Price. Money-saving machine shop that helps you make a profit on custom machined parts, automate the procurement tasks and reduce overall time ...


TOOL HOLDERS PROVIDE THE VITAL LINK TO MACHINING ...
www.secotools.com › article
Nov 26, 2019 - Tool holders represent less than two percent of total production costs. Even cutting that cost in half produces negligible savings, while a scrapped workpiece or ...

A Low-Cost Vision-Based Monitoring of Computer Numerical ...
www.ncbi.nlm.nih.gov › pmc › articles › PMC6832709
by H Kim - ‎2019 - ‎Cited by 1 - ‎Related articles
Oct 17, 2019 - To collect the data from HMI of a machine tool, ... In actual field conditions, because of a noisy environment of machining shop floors, ... However, the status of actual cutting can be ...

Setup Time Reduction - DSpace@MIT
dspace.mit.edu › bitstream › handle ›611148027-MIT
PDF
by H Guo - ‎2009 - ‎Cited by 7 - ‎Related articles
Dec 2, 2019 - machining station directly affects the manufacturing capacity. ... setup time has been reduced by up to 40 percent and the expected cost saving is about.

PRECISION VS CONVENTIONAL - Tamshell
tamshell.com › precision-vs-conventional
Jul 25, 2019 - A traditional machine shop offers conventional machining services. ... Precision CNC machining helps reduce material costs due to waste from operator error.


Sustainable Machining for Titanium Alloy Ti-6Al-4V | IntechOpen
www.intechopen.com › books › sustainable-machining-...
by I Masood - ‎2019
Jul 25, 2019 - Cutting tools having long tool life are preferred over those with short tool life in order to reduce overall machining cost and increase productivity. In aerospace ...


Kurt Machining Utilizes Live Tool Speed Increaser, Realizes ...
platinumtooling.com › kurt-machining-utilizes-live-tool...
Mar 22, 2019 - Calculating the reduction in machining cost per part and factoring the cost of the speed increaser, it was determined the use of the Heimatec product onboard the ...

Layout design for efficiency improvement and cost reduction
yadda.icm.edu.pl › yadda › element › 12_547-556_01...
PDF
by G Kovács - ‎2019 - ‎Cited by 1 - ‎Related articles
Jul 18, 2019 - costs in a significant manner. Facility layout design deals with optimum location of facilities (workstation, machine, etc.) on the shop floor and optimum material ...

Threading with maximum productivity and process reliability
03 July 2019
Walter AG is releasing the new TC620 Supreme thread milling cutter in diameters up to M20

Dry Swiss Machining in Medical : Production Machining
www.productionmachining.com › articles › dry-swiss-...
Jan 20, 2019 - While machining without cutting fluids and using a controlled production environment ... Program cost was reduced by $150,000 per year, and lead times were ...


unit-i: introduction of cim - tgpcet
www.tgpcet.com › MECH-NOTES › CIMS
PDF
Apr 25, 2019 - achieve production improvement, cost reduction, fulfilment of scheduled delivery ... stores the part programmes for all the components to be mechanical on a ...

Cryogenic Machining a Game Changer for… | Doosan ...
www.doosanmachinetools.us › news › cryogenic-machi...
Jan 14, 2019 - Well, that's the theory behind cryogenic machining. ... They also realized a 30% savings with cryogen over use of coolant (coolant cost plus coolant disposal ...

Machine Work ... - Industrial Engineering Knowledge Center
nraoiekc.blogspot.com › 2019/04 › machine-work-study-...
Nov 11, 2019 - Uploaded by Narayana Rao
products, reducing cost in manufacturing, lesser lead time and. [PDF]Machining Operations- Cycle Time https ...

Cellular Manufacturing: What's In a Workcell - Allis Roller ...www.allis-roller.com › cellular-manufacturing-whats-in...
Jun 24, 2019 - How Cellular Manufacturing Helps Machine Shops Stay Lean ... The goal is to reduce lead time and operating cost, while increasing labor flexibility and labor ...

How are Air Compressors used in Machine Shops? - Chicago ...www.cp.com › en-us › compressors › news-and-events
Aug 10, 2019 - A traditional workday in a machine shop requires the use of air compressors to ... the manufacturing process by reducing machining accuracy and can eventually ... Water Recovery Filtration: Recycling water is a huge cost saver for any shop.

5 Must Do's To Fix Your Shop Floor – Global Shop Solutions
www.globalshopsolutions.com › blog › 5-must-dos-to-f...
Mar 26, 2019 - The more data you have about how your machines and employees are ... Improve direct labor reporting and reduce indirect labor costs by measuring how much ...

How to Use Fact-Based Negotiation to Get the Best Price on ...
www.apriori.com › blog › how-to-use-fact-based-negot...
Nov 6, 2019 - Conducting fact-based negotiations is an effective cost reduction strategy when ... manufacturing process costs; the main forming process; any extra machining ...

9 Tips to Reduce Manufacturing Costs on New Designs and ...
www.cadcrowd.com › blog › 9-design-and-engineering...
Jun 11, 2019 - This applies largely to CNC machining and can be the cause of significant price discrepancies due to relatively small design flaws. To optimize this part of the ...

How to Reduce Production Cost in Manufacturing | Williamson ...
www.williamsonir.com › Maintenance
Jan 10, 2019 - How to Reduce Operational Costs While Meeting Increased Customer Demands ... If your machines are older, you can purchase devices like industrial ...

Manufacturing Software & Systems Solutions - ITC, Inc.
www.itccnc.com › manufacturing-software--systems-sol...
Aug 2, 2019 - ... Cost reduction; Tooling analysis/selection; Machining safety; Manufacturing planning; Software implementation/migration; Manufacturing System Integration ...


Cutting the cost and time of tooling for composites ...
www.compositesworld.com › blog › post › cutting-the-...
Jul 2, 2019 - “They would first have to machine a master and then laminate and demold a tool from this before final surface machining. We've calculated our 360 product can ...

What is 5-Axis Machining? | Astro Machine Works
astromachineworks.com › Blog
Oct 28, 2019 - 5-axis machining is an advanced cutting method that utilizes CNC to create some of the ... You could be missing out on cost savings in labor reduction, quality ...


10 Effective Cost-Saving Tips for Manufacturers - xTuplewww.xtuple.com › blog › 10-effective-cost-saving-tips-...
Feb 20, 2019 - 10 cost-saving tips to cut manufacturing costs without cutting personnel or creativity. ... Today, with advances in sensing and machine learning, robots are more ...



A Guide to Laser Cutting and the CNC Laser Cutting Machine
www.thomasnet.com › custom-manufacturing-fabricating
Mar 19, 2019 - We look at the CNC laser cutting machine, including process and machine ... and job shops must find a balance between processing costs and equipment costs ...

aerospace •additive manufacturing - PNAA
www.pnaa.net › images › Events › NExT › Presentations
PDF
Apr 26, 2019 - Reduce cost compared to metal tooling. •. (45%-80% less cost). • Reduced lead time – no need to wait on the machine shop. •. (80-90% faster). • Reduce weight.

Manufacturing Software: All-In-One (ERP, MES, QMS, CMMS ...www.proshoperp.com
Apr 23, 2019 - A shop management system for small to medium manufacturing companies. ... ProShop was built on the shop floor of a machine shop for nearly 20 years, and it's not ... At the end of the day, being in business comes down to profits. ... when estimating cost and lead time, and watching the work move though the shop in real ...

More Broaching Job Shop Listingswww.broachingjobshops.com › more-broaching-job-sh...
Mar 13, 2019 - By rapidly removing metal, minimizing handling, and providing around the clock operations we can pass significant cost savings, reduce potential for human ...


How to Cut Costs Without Sacrificing Customer Experience in ...
cb4.com › blog › costs-saving-ideas-in-retail
Jan 3, 2019 - According to a recent study by McKinsey, the most costly in-store operating expenses ... to machine learning tools that reveal what's happening in individual stores. ... For more cost saving ideas in retail, you'll want to take a close look at your ...

CNC Machining Articles | Advantage Machining
advantagemachining.ca › news
Jan 20, 2019 - 13+ years of machine shop experience - follow our CNC Machining Articles to better ... Extending Tool Lifespan and Cost Reduction Through Coolant Drilling ...


Inside Maxim Oil – Maxim Oilw
ww.maximoil.com › home › home-blue-office › insid...
Mar 18, 2019 - An alternative, machining with “minimum quantity lubricant,” or MQL, is gaining acceptance as a cost-saving and environmentally friendly option in place of some ...

5 Must Do's To Fix Your Shop Floor - Panorama Consulting
www.panorama-consulting.com › storage › 2019/03
PDF
Mar 5, 2019 - reduce cost on the manufacturing shop floor. Everyone in manufacturing knows increasing efficiency and productivity of both machines and employees is one.


Multitasking Machining Centers Double Throughput, Cut Costs
www.moldmakingtechnology.com › blog › post › mult...
Mar 8, 2019 - Results: Significant reduction in setups, virtually eliminating down time between setups. Faster machining, better accuracy and fewer mistakes reduced lead times, ...


10 Ways Machine Learning Is Revolutionizing Manufacturing ...
www.forbes.com › sites › louiscolumbus › 2019/08/11
Aug 11, 2019 - The leading growth strategy for manufacturers in 2019 is improving shop floor ... increasing production throughput by 20%, reducing maintenance costs 30% ...

10 Common Problems with CNC Machine Tools (And How to ...hwacheonasia.com › 10-common-problems-with-cnc-m...
Aug 2, 2019 - As one of Asia's leading CNC machine tool manufacturer, we're aware of the common problems and issues that may occur during the machining process. ... Choosing the wrong cutting tool for the job may often result in poor quality ... Uses of CNC Lathe; Programming CNC Lathe; Types of CNC Lathes; Price of CNC Lathe ...

Manufacturing conversion cost reduction using quality control ...
agris.fao.org › agris-search › search
by V Shivajee - ‎2019 - ‎Cited by 4 - ‎Related articles
Jul 21, 2019 - Manufacturing conversion cost reduction using quality control tools and ... three main processes: machine shop, frame plant (weld and paint shop) and assembly ...

29 Cost-Saving Sustainability Ideas for Businesses
www.thebalancesmb.com › ... › Resources
Oct 15, 2019 - Cost reduction has always been important in business. Increasingly, however, companies must balance cost with green aspirations and improve both.

Reduce Costly Machine Downtime With Preventative ...shoplogix.com › preventative-maintenance-software › r...
Jul 11, 2019 - Direct Labor Costs – To calculate this cost, take the full length of machine downtime and multiply it by the hourly rate of the machine operators. Are there other ...

Industry 4.0: Capturing value at scale in discrete ... - McKinsey
www.mckinsey.com › media › mckinsey › industries
PDF
Jul 15, 2019 - Benefits. Machining OEE optimization reduces production cost by lowering machine hourly rates through productivity increases and the reduction of lead times, in ...

How to Reduce Cost of Quality with Industry 4.0 - Tulip.
cotulip.co › blog › how-to-reduce-cost-of-quality-with-in...
Mar 8, 2019 - They can easily track the process, machines, and people involved. Speed of Improvement. Data availability and data integrity shift shop floor discussions. Instead ...

Plant heads think lateral - People - Manufacturing Today India
www.manufacturingtodayindia.com › people › 3985-pl...
May 3, 2019 - ... us from the cost point of view. Bajaj Auto has moved towards Vertical Machining Centres (VMC) from HMC as it helps bring down the CNC costs," he adds.

Making Tracks: New Cutting Tools for the Railway ... - Iscarwww.iscar.com › Iscars_World_Brochure_2019_1
PDF
Feb 1, 2019 - Connecting New Genereation Tools to New Gen Machining Centers. 40 ... to simplify production, reduce costs, and maximize productivity in this challenging ...


How to Boost Efficiency and Cut Costs with Quick Change ...
www.triumphtool.com › metal-working-tools-blog › ho...
Apr 16, 2019 - The common practice of changing fixtures within a machining center without a ... that can drastically improve a machine shop's efficiency by reducing setup time.


6 Tips To Reduce Maintenance Management Costs
www.smglobal.com › blog › 6-tips-to-reduce-maintena...
Apr 9, 2019 - Facilities & equipment maintenance management costs going out of control? Here are some tips and maintenance cost reduction strategies. ... For example an unusual noise during machine operation that may signal a potential bearing failure ...

Research Papers 2019


Full article: Application of the single-minute exchange of die ...
www.tandfonline.com › doi › full
by RB Ribeiro - ‎2019 - ‎Related articles
Apr 27, 2019 - As a result, the complexity of setups and manufacturing costs are reduced, which ... which works with precision machining of molds and components for molds.

Eco-Friendly Cutting Fluids in Minimum Quantity Lubrication ...
link.springer.com › article
by B Sen - ‎Cited by 10 - ‎Related articles
Oct 15, 2019 - During machining of modern alloys, extreme heat energy, and cutting forces ... [168] claimed that MQL technology could reduce the machining cost up to 95%.

Multi-objective optimisation for minimum quantity lubrication ...
journals.sagepub.com › doi › full
by J Mumtaz - ‎2019 - ‎Related articles
Apr 22, 2019 - Minimum quantity lubrication method is very effective for cost reduction and promotes green machining. Hence, this article focuses on minimum quantity ...

Labour Productivity Improvement in an Automobile ..
.www.ijitee.org › wp-content › uploads › papers
PDF
Sep 6, 2019 - automobile component machining line by applying the ECRS ... Vertical Machining Centre, Throughput Time, Labour ... reduced costs and increased flexibility.


Determination of Cost-Effective Range in Surface Finish for ...
researchrepository.wvu.edu › cgi › viewcontentPDF
by MF Alahmadi - ‎2016 - ‎Related articles
Oct 8, 2019 - The main objective in machining is to produce high-quality products while minimizing production costs. Cost consciousness with respect to the metal cutting ...

Reducing the Risks during the Purchase of Five-Axis ... - MDPI
www.mdpi.com › pdf
PDF
by LI Cioca - ‎2019 - ‎Cited by 2 - ‎Related articles
Jan 9, 2019 - for vertical machining centers (complex machine-tools with numerical control). The selection attributes taken into consideration by this approach were: cost, ...

Friday, July 31, 2020

Cutting Tools for Machine Tools - Cost Reduction Opportunities



Topics in Chapter 4. Cutting Tools (Stephenson & Agapiou)

4.1 Introduction

4.2 Cutting-Tool Materials
4.2.1 Introduction
4.2.2 Material Properties
4.2.2.1 High-Speed Steel (HSS) and Related Materials
4.2.2.2 Sintered Tungsten Carbide (WC).
4.2.2.3 Cermets
4.2.2.4 Ceramics
4.2.2.5 Polycrystalline Tools
4.2.2.6 Polycrystalline Cubic Boron Nitride (PCBN)
4.2.2.7 Polycrystalline Diamond (PCD)

4.3 Tool Coatings
4.3.1 Coating Methods
4.3.2 Conventional Coating Materials
4.3.3 Diamond and CBN Coatings

4.4 Basic Types of Cutting Tools

4.5 Turning Tools
4.5.1 Indexable Inserts
4.5.2 Groove Geometry (Chip Breaker)..
4.5.3 Edge Preparations
4.5.4 Wiper Geometry
4.5.5 Insert Clamping Methods
4.5.6 Tool Angles
4.5.7 Thread Turning Tools
4.5.8 Grooving and Cutoff Tools
4.5.9 Form Tools

4.6 Boring Tools
4.6.1 Single Point Boring Tools
4.6.2 Multipoint Boring Tools

4.7 Milling Tools.....
4.7.1 Types of Milling Cutters
4.7.2 Cutter Design
4.7.3 Milling Inserts and Edge Clamping Methods

4.8 Drilling Tools
4.8.1 Twist Drill Structural Properties
4.8.2 Twist Drill Point Geometries
4.8.3 Spade and Indexable Drills
4.8.4 Subland and Step Drills
4.8.5 Multi-Tip (Deep Hole) Drills
4.8.6 Other Types of Drills
4.8.7 Chip Removal
4.8.8 Drill Life and Accuracy
4.8.9 Hole Deburring Tools

4.9 Reamers
4.9.1 Types of Reamers
4.9.2 Reamer Geometry

4.10 Threading Tools.
4.10.1 Taps
4.10.2 Thread Mills.

4.11 Grinding Wheels
4.11.1 Abrasives
4.11.2 Bonds
4.11.3 Wheel Grades and Grit Sizes
4.11.4 Operational Factors

4.12 Microsizing and Honing Tools
4.13 Burnishing Tools




Cutting Tool Materials


Ceramics - Ceramic Tools

Ceramic cutting tools can be divided into four categories

1. Alumina and Alumina mixed with zirconium oxide
2. Alumina-titanium carbide composites
3. Reaction-bonded silicon nitride (Si3N4, RB)

Si3N4 is the most appropriate ceramic tool material for machining cast iron at a speed up to 1200 m/min.

  4. Silicon carbide whisker-reinforced alumina, [SiCw-Al2O3]

Polycrystalline Diamond (PCD)


PCD, the hardest of all tool materials, exhibits excellent wear resistance, holds an extremely sharp
edge, generates little friction in the cut, provides high fracture strength, and has good thermal
conductivity. These properties contribute to PCD tooling’s long life in conventional and high speed machining of soft, nonferrous materials (aluminum, magnesium, copper, and brass alloys),
advanced composites and metal-matrix composites, superalloys, and nonmetallic materials. PCD is
particularly well suited for abrasive materials (i.e., drilling and reaming metal-matrix composites)
where it can provide significantly better tool life than carbide.

PCD is not usually recommended for ferrous materials due to the high solubility of diamond (carbon) in iron. However, they can be used to machine some of these materials under special conditions; for example, light milling cuts can be made in gray cast iron at speeds below 200 m/min.

PCD tooling requires a rigid machining system because PCD tools are very sensitive to vibration.

In mass production operations, the attainable tool life may be over 1 million parts (e.g., for
diamond-tipped drills or PCD milling cutters machining soft aluminum alloys). However,  tooling breaks due to vibration or rough handling might occur before wear becomes significant.

Grades of PCD  vary  between 1 and 100 μm.  Grades are grouped in several categories with average grain sizes of 1–4, 5–10, and 20–50 μm. The abrasive wear resistance, thermal conductivity, and impact resistance increase with increasing grain size, but finer grained tools produce smoother machined surface finishes. A coarse-grained PCD tool may provide 50% better abrasive wear resistance than a fine-grained tool, but produce a surface with 50% higher roughness. New laser-honing methods can reduce edge radii for coarse grained PCD and produce finer finishes with these grades. Because of their increased impact and abrasive wear resistance, coarse grades are preferred for milling and for machining high-silicon aluminum alloys and metal-matrix composites.

Multimodal PCD grades (made with bimodal, trimodal, or quadimodal distributions of PCD particles) provide the high abrasion resistance of coarse-grained unimodal grade with the high toughness and superior edge sharpness of medium-size grain tools. The PCD density increases with multiple particles sizes. Multimodal grades are less prone to chipping than unimodal grades.

Laser structuring has recently been applied to flat-topped PCD inserts to produce 3-D chipbreaking grooves and similar features, which have proven effective in ductile material applications
where chip control has traditionally been an issue.

PCD-tipped HSS or carbide rotary tools (e.g., reamers, end mills, drills, etc.) are available in
a limited range of geometries due to difficulties in grinding complex geometries, particularly on
small diameter tools. More complex geometries can be used on carbide rotary tools by sintering the
diamond into slots (veins) located at the point and/or along the flutes.

Issues to be resolved include identifying the optimal cutting edge geometry for the diamond
tip and the best method of pocketing the polycrystalline blank for strength and manufacturability.
The methods of brazing the polycrystalline/carbide substrate tip to the main tool body have been improving steadily, but one of the major failure modes is still the detachment of the polycrystalline tip or the wear and erosion of the braze joints intersecting the cutting edge. Wear and erosion of brazed joints is avoided when the diamond is sintered into veins within the carbide tool.

The point geometry, flute geometry, and web thickness have not been refined sufficiently to allow
use of polycrystalline brazed drills at penetration rates comparable to the feed rates attainable in
turning and milling. (Stephenson-agapiou)


BASIC TYPES OF CUTTING TOOLS
The six basic types of cutting tools are solid tools, welded or brazed tip tools, brazed head tools,
sintered tools, inserted blade tools, and indexable tools

https://www.productionmachining.com/search?q=PCD

Microsizing

Honing

Common honing tool designs: Single stone,  Multi-stone and Krossgrinding tool design

Brush honing

Burnishing Tools




Production Machining - Cutting Tool Case Studies

Systems Approach to Tooling

Advanced Turning Insert Selection - Mitsubishi Course
http://www.mitsubishicarbide.com/permanent/courses/75/index.html


17.1.2020
Pocketing with high speed router RAL 90

The RAL90 aluminium milling cutter is designed for extremely high metal removal rates. The extra robust cutter body with optimized insert seats sets the standard for a new level of process stability in high speed milling - ideal for heavy roughing to semi-finishing pocketing of aerospace frames in aluminium alloys.

In applications requiring even higher metal removal rates, the new RAL90 Super MRR milling cutter can reach extra high spindle rotation, e.g. up to 33000 RPM for DC 50 mm compared to 23500 RPM for RAL90. This means a 40% productivity increase.
Machining aluminium for lighter and better recyclable vehicles
https://www.sandvik.coromant.com/gb/News/technical_articles/pages/machining-aluminium-for-lighter-and-better-recyclable-vehicles.aspx

Options, Benefits and Applications of Machining with Ceramic Turning or Milling Inserts
26/06/2019
https://www.cutwel.co.uk/what-are-the-benefits-of-machining-with-ceramic-turning-or-milling-inserts

12.2.2019

Kennametal’s KBH10B and KBH20B grades are designed for hard turning. They are available in double-sided inserts for materials as hard as 65 HRC.  The inserts are  for “high-volume production of hardened gears, shafts, bearings, housings and other drivetrain components. A ceramic binder structure and TiN/TiAlN/TiN coating provide extreme wear resistance even at elevated cutting speeds.  A gold PVD coating makes it easier to identify when an insert needs indexing, while the numbered corners ensure that a machine operator does not inadvertently switch to a used edge. Edge preparation in a “trumpet-style” hone, is  for heavier and interrupted cuts. a
A light hone edge inserts are for continuous turning. Both inserts give extending tool life and generate surface finish values as low as 0.2 Ra.
https://www.mmsonline.com/products/pcbn-inserts-from-kennametal-make-hard-turning-more-cost-effective

2014-07-29 (Reg Ral 90)
An optimally designed, high-precision insert seat with seat numbering ensures a maximum runout accuracy of 20 microns axially and 15 microns radially, a feed rate of 0.3 mm/tooth and cutting depths of up to 14 mm.
https://www.sandvik.coromant.com/en-gb/news/press_releases/pages/ral90.aspx

Sandvik Coromant 2020 catalogues
https://www.sandvik.coromant.com/en-gb/downloads/pages/default.aspx


Optimization in Tool Engineering Using Geometric Programming
Don T. Phillips &Charles S. Beightler
Journal: A I I E Transactions
Volume 2, 1970 - Issue 4
Pages 355-360 | Published online: 09 Jul 2007
This paper explores the use of geometric programming to solve tool engineering problems. The primary objective is to relate the technical factors involved in the cutting process to the economics of a particular tooling operation, and from this relationship determine the optimum speed and feed resulting in minimum cost per machined piece. Solution techniques are presented for non-linear objective criteria, subject to both linear and non-linear constraints. Computational procedures are illustrated through the solution of two typical examples.

https://www.tandfonline.com/doi/abs/10.1080/05695557008974776?journalCode=uiie19


YG-1
YG-1 is one of the world’s 5 major companies in the End Mill manufacture and sales industry

and also the largest in the Republic of Korea

Based on its 38 years of know-how, YG-1 is expanding diversification of items.
http://www.yg1.co.kr/about/ourcompany.asp


Updated on 24 July 2020
 1 May 2020,  9 April 2020,
29 March 2020