How to enhance efficiency of machining process

January 6, 2016 12:05 pm

An analysis on the need for enhancing the efficiency of machining process
Why the need?“The continuing advances in production methods in manufacturing industries such as automotive components, pumps and valves have created a need, not only for precision work holding devices but also for efficient machining process.  This is true for hard-to-hold and non-cylindrical components,” believes K Jagannathan, Executive Director, Sales & Marketing, Guindy Machine Tools.
Jagannathan explains his statement with an example – the production and machining of components with intersecting axes, has, for a long time involved high processing expenditure. These components were either processed on special machines, transfer lines or on conventional lathes in several chucking operations. This is a time consuming process and we have to retain accuracy during each chucking operation.
To machine such components efficiently and to save time yet retain accuracy, ideal solution would be to machine the component in a single setting on a standard machine. This calls for a special chucking system which can perform multiple operations in a single setting. This will result in enhanced production and cut machining time often by factors as high as four times, according to Jagannathan.
Talking on the need of efficient machining process for an OEM Nitesh Gupta, GM – Product & Business Development, Haas Automation says, “Efficient machining processes for industrial production lines at OEMs is crucial as it results in an improved production and utilisation of available resources.”
Factors contributing to production line efficiency are manpower utilisation and machine efficiency. Measuring the machine efficiency and man power utilisation should be on-line, accurate and truthful. The management should be able to look for relevant production data and to accurately interpret these data in order to identify the various faults at production level and to immediately take steps to improve efficiency.
Enhancing efficiency of machining processExpressing his views on how to enhance overall efficiency of machining process, Jagannathan says, “One of the ways to enhance the machining process is to use custom work holding devices. Since these work holding devices are built for a particular component, it takes care of any anomalies in the component, such as an overhang, by providing a balancing arrangement like Turbine Housing. But after a detailed study of the component we arrived at a work holding solution with Universal Ball Lock Chuck including a special balancing arrangement.”
Machine efficiency is one of the factors that are frequently overlooked by the management and this can lead towards losses which reduces the Overall Equipment Efficiency (OEE). Improper maintenance of machines will result in low standards of produced parts and increases the maintenance of machines. Machines are meant to work efficiently, but in some circumstances machines can be less productive due to improper preventive maintenance.
Gupta observes, “Preventive maintenance is a key factor that keeps the machine running efficiently through the production process. Total Productive Maintenance (TPM) is the need of the hour wherein unpredicted downtimes can be reduced and optimum usage of machineries can be achieved which will inherently result in higher profitability for the OEM.”
GMT’s SolutionsSpeaking on the products and solutions offered by GMT, Jagannathan proudly boasts, “A special team of designers, experienced machinists and manufacturing engineers work closely with our customers to provide custom work holding solutions to enhance production.”
Jagannathan has chosen three case studies at random where there are solutions to enhance production, such as components with extruded stock, non-cylindrical parts, eccentric, off-center and non-traditional applications. The case studies are as follows:

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