Manufacturing optimization

Manufacturing optimization can significantly reduce material consumption by reducing waste, protecting tools, and more precisely sizing raw materials. This can be achieved through the following measures:

• Numerical methods in method planning

The choice of manufacturing process can influence material consumption. For example, external high-pressure forming (AHU) leads to higher material consumption in the remaining flange compared to traditional deep drawing. Nowadays, method planning is supported by numerical methods (forming simulations), which enables quantitative statements about the material consumption of the respective process.

• Better knowledge of the material properties used

Knowledge of material properties can reduce reject rates. A statement about the suitability for forming can often be made based on the material analysis before a coil is cut.

• Sensory or optical process monitoring

Early detection of cutting breaks through sensory process monitoring can reduce rejects. This can be achieved with cutting tools by measuring force or sound emissions. With the sound emission measurement, cutting edge damage of approx. 1% of the total cutting length can be detected and its position determined.

• Waste minimization

Powerful software based on the Simplex algorithm can support waste minimization. However, it must be taken into account that although optimization reduces the material costs for waste, in return programming costs, storage costs, interest on stock parts or manufacturing costs can increase. Technological constraints (minimum distances between workpieces) or constraints from production planning (storage capacity, deadline, etc.) must also be taken into account.