Case Histories

Case History 2

In the example below, a machine-ready blank eliminated .98 minutes of time spent premachining a rough blank, including the handling and reclamping of parts. Machine-ready blanks cut over 16 hours off the throughput time of the job and saved $0.57 per part. This was achieved even after realizing a 100% increase in the material cost. Not only was this customer able to save about $570 but they were able to ship more product out the door with the 17 hours of throughput they gained.

Rough-Blank

Material: 5/16 X 1 1/8 X 1 1/8 (Oversize)
Quantity: 1000 pcs
Prep Machining: .48 min
Operator Intervention: .5 min (clamp changing)
Finish Machining: 6.55 min
Total Run Time: 7.53 min ea.

Machine-Ready Blank

Material: .250 X 1.000 X 1.000
Tolerances: +/-.001” Thickness, +/-.002” W/L
Flatness: within .002”
Quantity: 1000 pcs
Prep Machining: 0 min
Operator Intervention: 0 min (clamp changing)
Finish Machining: 6.55 min
Total Run Time: 6.55 min

Results

Machining cost savings: $1.23 / part
Material increase: $0.66 / part
Total cost savings: $0.57 / part

Total job savings: $570
Throughput increased: ≈0.98 minutes/part or 16.33 hours of machine time freed up for more jobs