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Manufacturers across the US are contending with a challenging set of circumstances. Overall costs are on the rise, competition is fierce, and customers are demanding more and more, for less.
This economic landscape requires manufacturers to reassess their spending, find ways to cut costs, and drive efficiencies.
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Manufacturers are always looking for ways to increase overall manufacturing efficiency, but it's more important today than ever before.
Improving cycle times reduces costs in a number of ways:
Savings here can be passed onto the business as a whole, and reduced cycle times could mean increased capacity.
Costs in general are on the rise across the globe. Inflation has been rising in recent years, some raw materials are in short supply, and various geopolitical issues create trade disruptions.
The result is that manufacturing costs can rise unexpectedly over a short period of time. This is why it's essential that your machining is as efficient as it can be, so you’re in a stronger position to absorb increased costs.
Manufacturers are also hunting for ways to get the most out of the machines and equipment they already have to reduce investment in new machining capacity. If a business can find hidden potential in their existing CNC machines, that’s a huge money saver compared to buying additional machine tools.
Where should you start?
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Vericut can simulate fully optimized processes with far greater spindle utilization, resulting in less idle time, and more time for manufacturing.
Manufacturers incur a huge cost from collisions, both in terms of machine damage and production downtime. Vericut Verification simulates machine movements to predict collisions and programming errors before they occur in real life.
This means unplanned downtime, repairs, and tooling damage costs can be avoided prior to actual cutting.
Traditional manual prove-outs can take hours of checking. These are costly from a labor standpoint, but also from a downtime perspective.
So how do you reduce manual prove-outs?
Vericut software allows for virtual prove-outs to reduce physical runs, freeing up machine and personnel time, while also reducing risk.
This means you can be confident you’re making the right cut every time - even on parts you’re running for the very first time.
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Vericut CNC optimization software is the perfect tool for elevating machining efficiency.
It does this by:
These improvements mean saved energy, maintenance costs, and tool consumption on every part. In the long run, these savings add up, helping to slash overall machining costs.
Vericut Force CNC Optimization software is particularly powerful for optimizing large batches. Simulate one part, validate the code, and scale the results to your low-mix, high-volume manufacturing.
The software also detects potential errors early on, saving costs on mistakes and scrapped parts.
Did you know?
Happy with your current CAM system and verification? You can also opt for Vericut Optimizer - a standalone product that will allow you to perfect your machining processes without the need for a Vericut license.
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Tooling costs can quickly add up when manufacturing large quantities of components from tough materials. Beyond expected wear and tear, unexpected breakages can also cause scrapped parts and downtime.
It's essential to choose the right tools and maximize their lifespan. This minimizes downtime and wastage. Simulation-based toolpath refinement helps you get the most from your tools while also determining the viability of a more economical tool choice.
An idle machine is a costly machine, so manufacturers looking to slash machining costs should minimize repairs, downtime, and maintenance.
Again, optimized toolpaths, cutting forces, and feeds will help you get the most from your CNC machines by balancing load and wear with productivity.
Plus, predictive simulation helps engineers identify stress areas that would prematurely degrade machine tools and spindles.
Coolant is frequently overlooked in cost reduction strategies, but its role is essential.
It is not a ‘set and forget’ aspect of machining. Its concentration, type, and delivery method significantly impact efficiency, component quality, and equipment longevity.
Improper applications can negatively affect tool wear, surface finish, and accuracy. It could even contribute to scrapped parts. In short, it’s costly not to perfect your use of coolant.
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Digital tools are a fast-growing facet of modern manufacturing, and for good reason. Manufacturers who harness intelligent digital technologies find ways to save time others can't, lowering their cost-per-part.
Machining setups are time-consuming and labor-intensive, especially for high-mix, low-volume manufacturing. Vericut simulates setup procedures, allowing for smart adjustments before physical setup.
Plus, with Vericut AUTO-DIFF™, engineers can compare their CAD design models to a simulated CNC machine to check for differences and weaknesses, helping to guarantee components are manufactured right the first time..
Automation, including physical robots and software-based machine learning, is playing a key role in reducing engineers' machining costs.
Robots automate repetitive and time-intensive tasks like loading, tool changes, and part inspection. These are costly from a labor perspective, but efficient and fast when using robots, meaning your people can put their skills to work on more meaningful tasks.
Automated CNC machines can also operate longer without machinist intervention, even through the night in certain cases. This boosts output per CNC machine, lowering costs.
Many businesses take this concept to the next level with lights-out manufacturing, where manufacturing facilities operate around the clock with minimal human intervention. In this case, robust software and machine learning are a necessity.
These robots are best paired with Vericut simulation software to expedite and improve their deployment across a facility.
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