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Proper tool Management improves profits

Source: Release Date:2010-05-04 135
Effective competition is more than pushing parts out the door. Increased machining productivity is critical to any shop's survival, but cost savings can present itself in some surprising ways. Cutting tool management leads to increased profits: managing cutting tools and consumables as they move around the shop floor. Cutting tool management, in the material sense, includes the appropriate choice and use of cutting tools, as well as continuous monitoring of unwanted phenomena on cutting tools during the period of cutting, e.g. breakages, intensive wear and overload of the cutting edge. Appropriate cutting tool management, in the financial sense, means decreasing costs over a period of time. Shortening of cutting time is possible to achieve with the use of tools with better cutting performances. Decreasing production time can be also achieved by multi-purpose processing, parallel processing, with a quick change of tools, which are placed into the tool magazines of machines. If improper manufacturing resources, machine tools and procedures, are applied or if improper use of these resources arises, unfavourable future comes. The first step during tool management implementation is to establish a data base of cutting tools, to ensure a communication between computers and personnel dealing with tools, located in several departments of the company. Communication and access to certain tool data is based on code for every cutting tool, which is actually a classification key. There have been several models for tool supply in a group of machines to overcome the short supply of tools. The optimal frequencies of distribution and the optimal ordering cycle as decision parameters is proposed for the tool supply to a group of machines based on the depot system. Cutting tools, participates with about 2-4 % in the structure of the production costs, so it can be concluded that the result of cutting tool savings by 30-50 % contributes by only 1 % of the total cost. Oppositely, if machining parameters increase with 20 %, the cutting costs will decrease with 15 %. Implementation of cutting tool management system has been analysed as the most important phases of cutting tool flow through company: in time availability and best exploitation on machines. While analysing availability as the greatest interests were focused on determination of minimal number of tools and employees in company dealing with tools and number of cutting tool suppliers. The supply and selection of appropriate cutting tools has become a very complex task, regarding both the number of their producers and suppliers and a very complex classification and distinctive characteristics of tools. The costs for purchase of the tools represents a direct production cost (on average 2-4 %), and can be far greater considering exploitation conditions of the tools. However, by rationalising the exploitation conditions, operating regime, and by the appropriate choice of cutting materials, significant savings can be achieved, whereas production costs can be decreased. Selection of tools The selection of cutting tools, which will be used on CNC machines includes the choice of the inserts and it is usually chosen by CNC programmers, i.e. it is based on the tool lists made by the CNC programmers. Since there is no established system for choosing the best supplier/producer, inserts are usually delivered from familiar suppliers/producers, without further market research regarding the best characteristics of inserts from various other producers. Cutting tools suppliers conduct periodical control examinations of cutting possibilities of newly developed inserts which replace the existing ones. The cutting insert of a certain supplier with better performance will replace the insert of poorer performance, so that it has higher priority in the supplying system. The needed amount of cutting inserts can be relatively quicAir Jordan
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