A cost reduction method that significantly reduces processing man-hours by integrating the removal of small-diameter screw machining and difficult-to-maintain shape components.
A case of significant cost reduction achieved by integrating a split-type unit that gathers parts for grinding processing into MC cutting processing through VA and VE. The key point is to reduce processing man-hours significantly by transitioning from labor-intensive grinding processing to integrated MC cutting processing. VA, VE Information: Original Shape Material: SUS430 Key Material Shape Parts: 5×5×300, 16 pieces Key Material Receiving Blocks at Both Ends: 30×30×200, 2 pieces After VA, VE: Material: SUS430 The processing of 64 M2 screws (4 screws for each of the 16 key material shape parts) is prone to tap breakage defects. Improving this and finishing the key material shape through grinding processing requires a lot of man-hours. By switching to MC processing, this led to a significant reduction in processing man-hours, thus resulting in cost reduction.
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○Situation Before Improvement○ Material: SUS440C Outer Diameter Shape: 350*200*30 【Before Improvement】 ●The shape is 30mm thick on both sides in the 350 direction, with a thickness of 5mm in the middle. Here, 36 grooves with a length of 350mm and a width of 1.3mm are processed. Currently, to create these grooves, 36 bars of key material (3*5*350) are produced. Additionally, to screw the key material and block together, M2 taps are drilled in 72 places at both ends. As a result, the finishing process is grinding, which significantly increases processing time and burden. Furthermore, great care is taken in processing the M2 taps. ↓ 【After Improvement】 ●The blocks at both ends and the key material are integrated, and the 1.3mm groove processing is done with a machining center using 1.3mm wide slice teeth. ●Cost Reduction Effect: Existing product costs 3 million yen ↓ Reduced to 1.1 million yen as a unit (63% cost reduction). ○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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