Despite the significant investment that a new machine represents, the fact that around 70 percent of machines are purchased un-tooled means that many manufacturers are still missing opportunities to reduce payback times and improve the Return-On-Investment (ROI) from their capital outlay.
Achieving the best possible ROI requires recognition that a machine purchase is only one element of a successful installation. Carefully planned machine investment strategies should encompass both capital machine purchase and a detailed assessment of the best methods and tools for the chosen production task.
Time taken as early as possible in the planning stage can pay dividends in terms of reducing the total cost of acquisition in terms of a smooth installation, shorter run-off period, minimum business disruption, reduced cost-per-component and the earliest possible payback.
Indeed, in some cases early identification of the best approach and tooling solutions may even present the opportunity to further improve ROI through the purchase of less expensive machines than originally planned.
Capturing The Benefits Of Smart Tooling
As mentioned, smart tooling solutions can play a part in improving ROI. For instance, the Coromant Capto toolholding system is designed to rationalise the tool management process through the use of a single system for both turning and rotating tools. The toolholding system is said to provide repeatability and rigidity, facilitating the highest possible metal removal rates.
According to the manufacturer, no modifications are needed — standard tools can be used straight away. Tool changeover times are typically reduced from 10 minutes to 60 seconds, which can mean a saving of around €50,000 (US$56,590) a year on a typical CNC lathe.
Without a doubt, tooling has a big influence on ROI. For instance, while milling is demonstrably better for roughing and semifinishing operations than rival processes, even when the need for straightforward turning is required, turn-milling with an endmill or facemill may be a better solution with regard to metal removal rate.
Similarly, drilling is usually most efficient using an indexable insert short-hole drill. However, when there is a variation in hole sizes along with limitations to tool magazine stations or spindle power for large diameters, the flexibility of an endmill producing holes by helical interpolation may well be the best way forward.
Close Liaison
Away from tooling matters, cutting tool producer Sandvik Coromant has a support service that helps manufacturers to get their investment strategy ‘right from the start’. The service, called ‘Machine Investment’ (MI), considers how OEMs, machine tool agents and tool manufacturers can all work together to deliver the best possible outcome for a given environment.
Calling it a step-by-step approach designed to save time, trouble and money, the service defines, both in technical and commercial terms, the end user’s needs and the new opportunities that investment can bring.
A team from the cutting tool producer is created to work closely with the customer and the machine manufacturer to ensure that these requirements are realistic and achieved. All key specialist players are involved at the earliest possible stage, including software, clamping and coolant suppliers.
The focus is on priorities such as production costs and output, with discussions typically involving capacity objectives, process definition, choice of machining method, component machining costs, cycle times, tooling requirements, programming, workholding, process flexibility, quality, unmanned operating possibilities, predictable tool life and toolholding/changing.
Up-Front Planning
From experience, the cutting tool producer knows that if planning is not done correctly, the result will be extra costs for new tools and the loss of key people to other commitments. Also, the machine often becomes very busy very quickly and it gets hard to find the time to address issues, which in turn leads to reactive ‘fire fighting’ rather than proactive planning.
By spending a little more time and effort in the beginning, those adopting MI practices will experience less surprises and frustrations, and come out ahead in the long run.
This is about more than just equipping the machine — MI support relies on a combination of tools, tooling solutions, service and industry experience to help attain higher productivity, faster throughput, more rational tool management and reduced downtime.
