Optimising machining processes is essential to improve efficiency and reduce costs at Mebsa, a leader in the machining sector in Barcelona. Implementing advanced practices in design, material selection and tooling can have a significant impact on a company’s production and competitiveness. This article provides key recommendations for optimising machining processes, focusing on identifying and eliminating operational inefficiencies.
Techniques to increase efficiency
To maximise efficiency in Mebsa’s machining processes, we implement several techniques, such as:
- Prioritisation: prioritising tasks according to their impact on production allows us to optimise time and resources.
- Automation: incorporating automated machinery reduces lead times and improves job accuracy.
- Improved programming: proper programming of CNC machines and the use of CAM software helps with more efficient cutting speeds and paths.
- Staff training: training operators in advanced techniques and technologies increases skill and decreases the margin of error.
Implementing rapid improvements
Rapid improvements are those that can be implemented immediately without requiring large investments. Some of these can be:
- Reorganisation of the workspace: a clean and well-organised environment allows operators to work more efficiently.
- Establishment of standard procedures: defining clear protocols for performing specific tasks ensures greater uniformity and effectiveness of processes.
- Use of multi-functional tools: these tools decrease changeover time and increase versatility during machining.
Continuous process monitoring
Active monitoring at Mebsa is vital to ensure that optimisations are working and to detect new areas for improvement. This can be achieved through:
- Data management systems: implementing software that collects and analyses real-time data to detect anomalies.
- Establishing performance indicators: specific KPIs that measure the efficiency of the process and the fulfilment of objectives.
- Regular meetings: hold regular meetings with the team to assess the status of processes and discuss possible improvements.
Constant monitoring allows adjustments to be made to keep production at optimum levels.
Selection of materials for machining
The choice of suitable materials for machining is essential to achieve production efficiency and cost reduction. A well selected material facilitates the machining process and contributes to the quality of the final product.
Materials that are easy to machine
Materials that are considered easy to machine include those with characteristics that allow efficient cutting and a suitable finish. Examples include:
- Aluminium: This material has excellent machinability due to its malleability and low weight. Its use is common in the manufacture of light and strong parts.
- Copper: Although not classified as the easiest to machine, its high electrical and thermal conductivity make it popular in applications where special properties are required.
- Low alloy steel: These steels often combine strength and machinability, making them versatile for a variety of industrial applications.
- Engineering plastics: Many plastics such as Nylon and Polycarbonate are easy to machine and offer good corrosion resistance.
Cost comparison between materials
Cost analysis when selecting a material is critical to the economic success of a machining project. Comparing material prices can help get the right balance between cost and performance. It is important to consider:
- The price per kilogram of each available material.
- The associated indirect costs, such as machining time and tool wear.
- Storage and transport considerations, which can influence the total cost.
Machining tools
Machining tools are essential for the production of precision parts. Their proper selection, maintenance and use of innovations can significantly influence the efficiency of the machining process.
Selecting the right tools
The choice of the right tools is a fundamental aspect that directly affects the quality of the final product and production costs. The selection should be based on several criteria:
- Type of material to be machined: It is crucial to select tools that are adapted to the specific properties of the material, be it metal, plastic or composite.
- Tool geometry: Different geometries favour certain types of machining, such as milling for flat surfaces or turning tools for rounded profiles.
- Working conditions: Factors such as cutting speed and the type of coolant used must be considered when selecting the right tool.
Maintenance and tool life
Proper maintenance of machining tools is crucial to maximise tool life and ensure optimum performance. The maintenance strategies we follow at Mebsa include:
- Regular inspections: Checking the condition of tools to identify wear or damage in time.
- Sharpening and reconditioning: Regular sharpening improves cutting efficiency and prevents the generation of defective parts.
- Proper storage: Protecting tools from moisture and shocks will prolong their life. Using cases or storage structures is also recommended.
Multifunctional tools
Multifunctional tools have gained popularity in the machining industry due to their ability to perform several operations with a single tool. This offers several advantages:
- Reduced changeover times: By using tools that can perform multiple functions, the time spent changing from one tool to another during the machining process is reduced.
- Minimisation of inventories: Having fewer specific tools allows for more efficient management of inventory space and cost.
- Increased production flexibility: The versatility of these tools allows them to adapt to varied jobs and designs, adjusting to customer needs.
With these strategies, Mebsa can continuously improve its machining processes, increasing operational efficiency and market competitiveness.