Case studies of cost reduction through shape optimization by investigating the causes of frequent defects.
A case of cost reduction achieved by identifying the causes of frequent defects and optimizing the shape through VA (Value Analysis) and VE (Value Engineering).
There are often causes for parts that frequently fail, and by making these issues apparent and resolving them, it often leads to cost reductions. "Not producing defects" is a hidden method for cost reduction. In this part, there are frequent occurrences of cracking at the marked circular area, leading to defects, so we will investigate the causes and seek countermeasures. ■Examining the current issues We will consider where the cause of the cracking lies. It is believed that the sharp angles at the marked area and the extreme narrowness of the left side compared to other surfaces make it prone to distortion due to temperature changes during hardening, resulting in cracking. 【Before Improvement】 ●Material: SK3, Heat Treatment: 55 degrees HRC The corners were finished at 90 degrees, causing stress during hardening and leading to frequent cracking. 【After Improvement】 ●Successfully eliminated defects from cracking by dispersing the stress during hardening.
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The phrase 'not producing defects' is a hidden method for cost reduction. Since this component often experiences a high occurrence of cracking, which leads to defects, we will investigate the causes and seek countermeasures. Key Point: It is important to pursue the causes of defects in components that frequently produce them. VA, VE Content: Explore responses to areas where cracking frequently occurs. For more details, please contact us.
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In the process of improving design, we analyze the entire structure of the equipment, making it possible to solve all issues related to quality, delivery time, and cost. In terms of cost reduction, we achieve an average cost reduction of 40-50% (only applicable to machined products). In our past maximum achievement, we achieved an 80% cost reduction. Our company directly conducts value analysis and improvement design for our customers' equipment.