Know the utilization rate of real assets and effect

Time:2023-06-15 14:02:35
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source:WILDA CNC Machining

Asset management, data is collected, maintenance and tool management system are the main factor that improves workshop efficiency. According to association of Chinese mould industry the report 2006, the entrance of its mould estimates the exit amount that still exceeded a mould. However, in 2004~2005 year during, their mould export increased 50% , and mould import rises 14% only. They think, labour force is the main competition advantage that revitalizes economy, and capital cost of the whole world is in reasonable level over. Their circumstance according to real knowledge, made farther tentative plan to work efficiency, and will be put in the operation of craft implementation automation of potential flaw immediately. According to Plante of plastic 2005 industry&The research of Moran company reports, successful mould makes an enterprise using their device in order to exceed the utilization rate of fourfold before above, these companies dig latent capacity adequately, working with the means of 24/7 duty (graph 1a) . The pattern that successful company produces, its deliver the goods on average time is every mould 36 days, and relative to not quite successful company, its the average delivery time of every mould is 77 days (graph 1b) . Graph 1 (A) capital utilization rate (B) mould delivery time generally speaking, the company does not understand their real assets to use circumstance and its opposite to produce the effect of efficiency and delivery time. When encountering need to raise the challenge of manufacturing function, they focus the central issue on equipment and service issue normally, consider other factors rarely. The utilization rate ability that enhances equipment only enhances process capability, shorten delivery time. The reason die manufacturer with machine tool low utilization rate uses EDM discharge to machine machine tool and machining center a future life to produce commonly opposite bigger with complex part; However, the leak loss of a lot of occurrence particle, can waste much operation process capability. Of the machine tool debugging a setting is one endless, complex with the process that makes mistake easily. To produce a pattern, must install the program of a spare parts beforehand on the machine tool, configuration needs the material of treatment and necessary cutting tool. Generally speaking, the program of mould spare parts is very big, but some manufacturers still use means of low serial communication to download these programs. The wool blank of material also is very big, they must use the job to slant buy value and coordinate rotate setting value debugs the machine tool null. In the meantime, must measure the length of cutting tool and diameter, inside the chart of appearance of cutting tool geometry that inputs data CNC system next, and must undertake first try cutting, with adjusting cutting tool slant buy value. The leak loss of productivity also can be caused during machine tool shutdown. Setting mistake can cause machine tool damage. If do not have backup, sudden electric breakdown can bring about the crucial file that stores in CNC system to lose, to resume the production of the machine tool, the likelihood needs to cost a few days or the time rehabilitate of a few weeks. The function that although modernization produces equipment and CNC,controls a system is very reliable, but if undertake groovy maintenance in time,serve, may cause the stop work that does not have a plan. The treatment speed of the machine tool is according to the process capability of the machine tool fixed setting commonly, but high speed processing technique may change this kind of balance, the complex part of typical outline is machined in mould industry especially. The process designing of the spare parts member the permission craft such as condition of pair of feed speed, material, cutting tool, width and cutting deepness changes setting often very conservative. And because a lot of operator differring reason (include to lack experience) , the treatment speed of set of the member that may surmount process designing. Cutting tool maintains the stop work that causes, it is varied that its change, as operator and cutting tool agency different and different, very rare company makes relevant policy and system run the life of cutting tool. Some companies are used to the cutting tool that uses low cost and relatively inferior treatment speed, and some companies are willing to invest use high-powered cutting tool and use higher treatment rate. They think, it is more important to use asset and labour force efficiently. The quality technology ability that takes superabundant land also can cause the leak loss of work efficiency. Cheap facilities or debug improper installation to be able to cause different consequence, it decided whether the treatment operation of the mould wants to rely on manual polish and repair, still can use cutting of 0 public errand to machine. Machine tool and relevant craft efficiency may very poor, but important is not to want to make hypothesis immediately, hurried ground employs costly solution. Perhaps increase a few groom or solve technology issue to be able to avoid to invest enormous capital, win the get one's own back of an expectation. The enterprise must spend time to gather the information that produces a situation about workshop place, want to carry out the solution that affects lowest of the biggest, charge above all. This is the only method that continues to obtain progress, support energetically with getting those who supervise layer and worker, because first result can be prospective project,build a confidence and financial credit. If the materiality action of the data of leak loss circumstance that the graph produces efficiency in 2 treatment process does not have data, the company will feel devoted and much investment according to the individual. Although this investment is very enough, that also needs to cost very long time ability to achieve ROI result of the front. Investment may be transferred because of other small issues, because investment is much the scope of capital is limited, only a few people can get the influence of its benefit. Actually, to the investment of low fare, a large number of opportunities can produce tremendous effect to operating efficiency. Lesser project can arise relatively short-term ROI benefit, make produce a team to continue to be engaged in improving a project. Carry out a proof, method of first-rate low risk is being used inside constituent limits is practical. Collect data to be able to get a result that yields people to accept rarely artificially. Workshop worker and the bias that run a team may mask nitty-gritty. Because belong to resource concentrated model child, because this can collect very basic data only. Each branch collects the data of themselves only, when the data that who decide when need accordingly or shows is accurate, because the meeting discusses each function branch to the craft between improves measure and waste time. The machine tool nowadays, robot and quality test system have aether net function, allow to collect the data inside all sorts of limits automatically for the most part. Information of amount of cycle of the part that accurately record runs treatment on the machine tool, treatment, spare parts, error and other and main time, can understand the produces actually accurate situation inside the workshop, liberate resource thereby, its application is analysed at function and raise craft level to go up. From the point of a variety of viewpoints, same data can offer the most specific interior to run circumstance and potential problem actually. Every every operator, order and every machine tool are in different time paragraph makes analysis can discover special occasion. The per cent that produces efficiency loss through opposite, produce odds, breakdown average time interval (MTBF) , repair or repair is average time (MTTR) analysis, can announce same a different element in the problem (graph 3) . Graph circumstance of loss of leak of 3 production efficiency, use respectively it is per cent, OK to produce odds, MTBF and MTTR chart to try to show automation to data is collected and analyse a tool the whole course that takes a machine tool to manufacture efficiency, allow a manufacturer to differentiate the actual beneficial result that already confirmed through practice in the organization. Differentiate fast redound, low venture capital investment, build credit and solve numerous little problem, prevent larger automation investment, with winning expectant get one's own back. Asset is safeguarded and management of cutting tool life is in all treatment operations, the pressure that maintains the budget with cutting tool to be caused to the factory is the greatest, because these are daily cost. Even if daily maintenance and cutting tool technology, can produce tremendous effect to equipment, and hourly investment cost and the business management charge related its are forgotten constantly. But, only very few one part company can make policy or system, the cost cost that will manage or maintains cutting tool place to need or use efficiency. Some companies had invested purchased the computer to maintain administrative system (CMMS) or asset management system, but the progress circumstance that they appear to apply at making resource use plan and record job only. Preventive maintenance is the norms requirement according to the manufacturer or experience, make by time. This kind of practice often can bring about the upkeep costs that gives higher specified number. Some component, for example ball guide screw and slideway, just can arise when axial movement condition only wear away, and lube pump kind component runs according to regular period job only. Below the circumstance of electrify, circular fan kind component runs ceaselessly from beginning to end, and batteries just is below the circumstance that does not have power source use. Use high speed main shaft extensively in mould treatment to may happen wear away, but also be affirmatory according to the rate that its use and power. Asset maintains life management system (graph 4) can collect data from inside asset, affirmatory machine tool whether whether electrify, each axis moves and main shaft rotates, all sorts of data can be used at dogging accurately the loss rate of the spare parts. When life of the rest substance under extreme value when, can beforehand plan of formulate preventive maintenance. When any low cost component are approaching their maintenance life fixed number of year, also can include to be in maintenance plan, with reducing the interpose number to the machine tool as far as possible. Maintain the component with periodic limited number, also can use this one system government before its need to change. Graph the administrative intervention that administration of 4 substances life sets according to using a case, will be helpful for reducing direct upkeep costs, can avoid the loss of needless productivity. Maintenance team can use this one system to undertake lesser intervention, can prevent what appear when factory stop production to order goods commonly circumstance. Some companies investment ordered cutting tool inventory to run a system, it can control personnel to use for quality already, also can use for machine tool distributors. This problem depends on the cutting tool measure that plant institute uses, but won't affect integral beneficial result. Some operator change according to the sound in cutting process cutting tool, and a few otherer the outward appearance that handles personnel to rely on opposite morely to produce a part detects. Some operator can be on indicated value of the first negative apace changes cutting tool, and a few otherer operation personnel may need to use more synthetic method. These changeful elements can raise the use cost of cutting tool. System of cutting tool management can be used with form a complete set of system of CNC numerical control, OK also interiorly is used, the service life of monitoring cutting tool, or applied cutting tool maintains strategy (graph 5) . To machining center, cycle of the cutting time that every machine tool can collect every cutting tool, cutting and cutting power data. To electrode of EDM machine tool, also can collect similar characteristic data. Considering the technology of cutting tool, material and cutting application, every cutting tool can establish proper extreme value. Graph the cutting tool that management of life of 5 cutting tool reachs formulary extreme value to any premature failure needs to undertake investigating, so that be in,undertake an analysis later. The change that produces in cutting tool agency also can undertake an analysis, and formulate cutting tool maintains a plan, the different opinion of a hold is maintained in order to eliminate an operation to cutting tool between personnel. For every kinds the operation provides a variety of cutting tool, system of cutting tool management also can extend handling time. When cutting tool reachs extreme value, machine tool aux will be able to chooses a same cutting tool automatically. To EDM machine tool, perhaps need investment increases a kind of device changing a knife that contains manipulator. The supervisory workload that system of this kind of cutting tool management can make operate personnel falls lowest. This also is the machine tool realizes a substantial that nobody turn an operation, can have the operation of 24/7 duty. Be in the United States, the utilization rate of asset is having very big distinction between successful pattern production company and not quite successful pattern production company. According to the dimensions of the enterprise, asset management includes a lot of factors, in the machine tool debug the respect such as setting, shutdown, speed, small stand and craft ability the leak loss of efficiency of metropolis generation production. In the problem with special understanding, solution that forms a part, monitoring and the process that raise craft level, data collects the action with a decisive move. In initial stage, data will indicate the lowermost capital configuration that simple improvement needs, the investment that is future builds confidence. Be maintained especially and tool management system, an effect can have when it is managing 2 crucial treatment factors. Although the die manufacturer of American home is facing the challenge of service charge, but use active 24/7 duty to be helpful for improving treatment productivity, shorten delivery time, strengthen their competitive position in global market. CNC Milling CNC Machining