CNC & Precision Machining Cost Reduction & Kaizen
11 proposals
CASE #26
CNC & Precision MachiningScrap Rate
Giảm phế phẩm từ 50% xuống gần bằng 0 trên máy phay đứng: dùng đầu dò đo ngay trên máy để tự kiểm gá đặt, tự bù offset và phát hiện dao gãy→
Current Cost
$3,166 / mo
Potential Cost
$12 / mo
Potential Saving
$3,155 / mo100%
Payback
2.93 months
Annual Saving
$37,856
Total investment (purchase + effort)
$9,246
% of plan to break even
24%
CASE #23
CNC & Precision MachiningConsumable costEasy
How to Stop Grooving Tool Chipping and Surface Scoring by Choosing a Deeper-Rated Insert for Better Chip Clearance saving $1,204→
Current Cost
$548 / mo
Potential Cost
$448 / mo
Potential Saving
$100 / mo18%
Payback
6.15 months
Annual Saving
$1,204
Total investment (purchase + effort)
$617
% of plan to break even
51%
CASE #22
CNC & Precision MachiningCycle TimeEasy
How to Cut Machine Downtime, Inspection Cost and Scrap by Switching from a Power Chuck to a Collet Chuck - saving $1,228/year→
Current Cost
$764 / mo
Potential Cost
$662 / mo
Potential Saving
$102 / mo13%
Payback
2.08 months
Annual Saving
$1,228
Total investment (purchase + effort)
$212
% of plan to break even
17%
CASE #21
CNC & Precision MachiningConsumable costHard
How to Fix a Worn Micrometer by Replacing the Anvil and Spindle Instead of Buying a New One→
Current Cost
$540 / mo
Potential Cost
$0 / mo
Potential Saving
$540 / mo100%
Payback
< 1 days
Annual Saving
$6,480
Total investment (purchase + effort)
$8
% of plan to break even
0%
CASE #20
CNC & Precision MachiningConsumable costEasy
How to Regrind Drills with a Turning-Style Chipbreaker for Longer Tool Life on SUS316 saving $7,500 year→
Current Cost
$1,500 / mo
Potential Cost
$875 / mo
Potential Saving
$625 / mo42%
Payback
~8 days
Annual Saving
$7,500
Total investment (purchase + effort)
$170
% of plan to break even
2%
CASE #19
CNC & Precision MachiningConsumable costEasy
How to Achieve CNC Tooling Cost Reduction: Splitting a Combined Drill Bit to Save $74,953 a Year→
Current Cost
$6,446 / mo
Potential Cost
$200 / mo
Potential Saving
$6,246 / mo97%
Payback
~2 days
Annual Saving
$74,953
Total investment (purchase + effort)
$298
% of plan to break even
0%
CASE #18
CNC & Precision Machining
How to Stop Inner Chamfer Tool Chipping by Opening Up Chip Clearance Behind the Chuck saving $1,037→
Current Cost
$259 / mo
Potential Cost
$173 / mo
Potential Saving
$86 / mo33%
Payback
~10 days
Annual Saving
$1,037
Total investment (purchase + effort)
$27
% of plan to break even
3%
CASE #17
CNC & Precision MachiningCycle TimeMedium
How to Achieve CNC Turning Cost Reduction: A Fourth Tool Cuts Machine Time, Saving $14,415 a Year→
Current Cost
$2,886 / mo
Potential Cost
$1,685 / mo
Potential Saving
$1,201 / mo42%
Payback
~8 days
Annual Saving
$14,415
Total investment (purchase + effort)
$311
% of plan to break even
2%
CASE #14
CNC & Precision MachiningScrap RateHard
How to Achieve CNC Turning Cost Reduction: Eliminating Tool-Change Scrap with a FANUC Custom Macro B, Saving $30,021 a Year→
Current Cost
$3,002 / mo
Potential Cost
$500 / mo
Potential Saving
$2,502 / mo83%
Payback
~2 days
Annual Saving
$30,021
Total investment (purchase + effort)
$136
% of plan to break even
0%
CASE #5
CNC & Precision MachiningScrap RateMedium
How to Achieve CNC Turning Cost Reduction: A 3-Point Collet Contact Design Cuts Lathe Length Defects by 66.6%, Saving $45,070 a Year→
Current Cost
$6,143 / mo
Potential Cost
$2,387 / mo
Potential Saving
$3,756 / mo61%
Payback
~1 days
Annual Saving
$45,070
Total investment (purchase + effort)
$136
% of plan to break even
0%
CASE #2
CNC & Precision MachiningMaterial CostHard
How to Achieve CNC Maintenance Cost Reduction: Replacing Hardware Counters with a FANUC Macro Program, Saving $12,720 a Year→
Current Cost
$1,060 / mo
Potential Cost
$0 / mo
Potential Saving
$1,060 / mo100%
Payback
~8 days
Annual Saving
$12,720
Total investment (purchase + effort)
$272
% of plan to break even
2%
Factories applied
1