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Roadmap for HMLV Production In a HMLV production environment, first time part yield and consistent quality in production of non-identical workpieces is key. The objective is to provide customized products where the part in a one piece batch costs the same as a part in a million piece batch and immediate delivery is assured. Producing good parts from the start depends on establishing a trouble-free and reliable machining process. It currently is fashionable to point to the newest production techniques and digitalization technologies as solutions to machining problems. However, speed, consistency and flexibility always have been, and still are, based on a foundation of operational excellence as well an educated manufacturing staff with a positive mindset and motivation. (see sidebar).
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Before discussing digitization and optimization, it is necessary to look at the workshop operations overall, determine where waste of time and resources occurs, and develop methods to minimize it. After that, the emphasis shifts to process quality or reliability. A Zero-Waste Workshop Reducing lead times requires elimination of waste in the manufacturing process. A zero-waste workshop does not over-produce parts, fully utilizes workpiece material, and does away with extra movement for semi-finished parts. Wasteful and time-consuming activities in the machining process itself include production of burrs, bad surface 31 | Industry Asia Pacific | November 2019
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finishes, long chips, vibration, and machining errors that create unacceptable parts. Bad parts must be reworked or rejected and remade, either of which adds waiting time to the production process. Even producing part quality that exceeds customer requirements represents wasted time and money. Shops must realize that it is necessary to achieve only the lowest possible workpiece quality that meets customer specifications and functional requirements. If a part tolerance is five microns, achieving three microns is wasteful. Higher quality tooling and more precise operating processes will be required to meet the tighter tolerance, but a customer will not pay for the unrequested higher quality. The job will be a money-losing proposition for the shop. Respecting Constraints The first phase in establishing a balanced machining process is choosing tools with load capacity that meets or exceeds the mechanical, thermal, chemical, and tribological loads present in the metalcutting operation. Phase two involves selecting cutting conditions that recognize the constraints put on a machining process by real-world factors. A cutting tool possesses broad capabilities, but specific realities constrain the range of effective application parameters.