1. Design and Engineering Phase (Source Control, Maximum Potential)

Design for Manufacturing (DFM):

lSimplify geometric shapes: avoid unnecessary complex surfaces, deep cavities, extremely small internal corner radii, slender cantilevers, etc., which can increase machining difficulty and time.

lReduce machining features: Evaluate the necessity of each hole, groove, and thread. Features that can be machined with standard drill bits/milling cutters are cheaper than those machined with non-standard cutting tools.

lRelax tolerance requirements: Apply strict tolerances only on critical functional surfaces. Unnecessary strict tolerances can significantly increase machining time (which may require multiple precision machining) and inspection costs.

lConsider tool accessibility: When designing, consider the size and length of standard tools to avoid features that cannot be machined with standard tools or require special ultra long/ultra small tools.

lStandardization: Use standard aperture, thread, groove width, etc. as much as possible to reduce the number of tool changes and the need for specialized tools.

lMaterial selection: Choose materials that are easy to process and have lower costs while meeting functional requirements. Consider the availability of materials and price fluctuations. Sometimes choosing materials that are slightly more expensive but have better processability actually results in lower overall costs.

Effective communication:

lDesign engineers and machining engineers are involved in early communication, jointly reviewing designs, optimizing designs to reduce costs.

2. Process Planning and Programming Stage

Efficient CAM programming:

lOptimize tool path: reduce idle travel (fast movement), adopt efficient cutting strategies (such as high-speed milling, cycloidal milling, dynamic milling), maximize material removal rate, and reduce machining time.

lChoose the appropriate tool: Select the most cost-effective tool based on the material, characteristics, and machining requirements (considering tool life and cutting parameters). Balance tool costs and machining efficiency.

lOptimize cutting parameters: While ensuring quality, tool life, and machine capability, use the highest possible cutting speed, feed rate, and cutting depth to shorten the machining cycle.

lReduce the number of tool changes: Reasonably arrange the machining sequence and concentrate the operations using the same tool.

lSimulation verification: By utilizing the simulation function of CAM software, accidents such as tool collision and overcutting caused by programming errors can be avoided, reducing trial and error costs and workpiece scrap.

Process optimization:

lProcess concentration/merging: Complete as many processes as possible in one clamping (utilizing the advantages of multi axis machining centers), reduce clamping frequency and time, and improve accuracy.

lChoose appropriate clamp: Design or select fast, reliable, and versatile clamp (such as modular clamps) to shorten clamping time and improve repeat positioning accuracy. Avoid overly complex specialized clamps.

lEvaluate machining methods: For certain features such as holes and planes, evaluate whether CNC machining is the most economical way? Can faster drilling machines, milling machines, or wire cutting be used as alternatives? Or consider near net forming (such as casting, forging) with minimal processing.

3. Material Management

Maximizing material utilization:

lNesting optimization: For sheet metal machining, use professional nesting software to closely arrange the contours of the parts and reduce waste of corner materials.

lChoose the appropriate blank size: The blank size should be as close as possible to the final part size to reduce the amount of material that needs to be removed. Consider standard profiles or near net shaped blanks.

lRecycling of scraps: Establish a system to manage scraps for machining smaller parts or test samples.

lBulk procurement: For commonly used materials, consider bulk procurement to obtain more favorable prices (balance inventory costs).

4. Production and operation stage

Improve Equipment Effectiveness (OEE):

lReasonably arrange production plan: optimize production scheduling and reduce changeover time. Consider continuous processing of similar part families to reduce tool and fixture replacement.

lAutomation: Under appropriate circumstances, introduce automated loading and unloading (such as robotic arms and truss robots) to achieve "light off production" and improve machine tool utilization at night and on weekends.

Optimize tool management:

lMonitoring tool life: Establish a tool life management system to avoid premature replacement (waste) or excessive use (resulting in workpiece scrap or machine damage).

lGrinding and Reuse of Cutting Tools: Professional grinding of grindable cutting tools (such as hard alloy milling cutters and drill bits) to extend their service life and reduce costs.

lCentralized procurement and bargaining: Centralize the procurement of commonly used cutting tools to strive for better prices and supply conditions.

Quality control and reduction of scrap rate:

lProcess control: Set up online detection or first piece inspection of key dimensions during the machining process to promptly identify problems and avoid batch scrapping.

lRoot cause analysis: Conduct a thorough analysis of the waste products that have occurred, identify the root cause, and take measures to prevent recurrence.

lAppropriate testing methods: Balance testing costs and risks, avoid over testing or under testing.