From Integration to Division: Cost Reduction Methods for MC Machining Process Time Reduction with VA and VE
Achieved over 63% cost reduction through shape segmentation.
This is an example of how we were able to significantly reduce processing time, improve quality, and lower costs by dividing MC block parts with complex shapes that are difficult to machine into shapes that can be machined, using VA (Value Analysis) and VE (Value Engineering). Our company focuses on product design modifications through VA and VE, and improving products like this one from a monolithic structure to a split structure is one of the VA and VE methods we use to respond to our customers' requests for cost reduction. *For more details, please refer to the PDF document or feel free to contact us.
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Part Information: ○Before Improvement○ Material: SUS440C Outer Diameter Shape: 300×200×50【Problem Area】 ●It was processed into a T-slot shape to reduce weight. (Width 100 at the back, width 20 at the entrance, depth 30) The T-shaped slot was processed in three places against a width of 200, which took considerable labor. 【After Improvement】 We decided to split the plate into two parts, creating a flat plate section and an L-shaped section, and to fasten them together with cap screws (M5) to make it a single unit. The thickness surface, which requires precision tolerance, is ground and finished after being screwed together, maintaining the same quality as before. 【Improvement Effects】 By processing the two parts separately, it became possible to perform heavy cutting, resulting in a significant reduction in labor, shorter delivery times, and improved quality. ●Cost Reduction Effect: The existing product of the integral part was 3 million yen ↓ By splitting into units, it became 1.1 million yen (a 63% cost reduction). VA and VE can be utilized through horizontal deployment. Cost reduction is possible even with different types through equivalent deployment.
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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.