Cost reduction case study that achieves a reduction in processing man-hours through material optimization in difficult-to-machine materials.
The key to improving the machinability of difficult materials depends on whether rigidity is required or not.
The amount of cutting affects costs in proportion to the processing man-hours. By changing difficult-to-cut material parts to optimal materials based on specifications, we can reduce costs. The key is to identify parts that can be replaced with materials like aluminum and resin, which have lower cutting resistance. When considering the issues with SS and SUS material parts, we will think about possible solutions based on their poor machinability. There are cases where strength and rigidity are required from the parts, and there are also many instances where they are not required. In such cases, changing the material while keeping the same shape can open up avenues for cost reduction. We will consider solutions to this problem using Value Analysis (VA) and Value Engineering (VE).
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【Before Improvement】 ●Material: SS41 Lot Number: 50 pieces Considering material change for use in non-load-bearing areas 【After Improvement】 ●Proposal to change the material to black Delrin Since there was an M4 tap in the plate thickness section, the thickness was changed from 8T to 10T, and a helicoil was used Cost reduction effect: 3,500 yen → 1,500 yen ・Although it is a peripheral device for precision equipment, it often rotates without load, so changing from SS material to black Delrin and increasing the thickness helps to enhance strength ・There are many similar parts for this device, and significant cost reductions were achieved using the same method ○For 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.
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