Xuangan Hydraulic Branch Factory Reduces Tool Costs, Adjusts Processes to Unlock Hidden Potential and Cut Consumption
Summary: "The processing method has been improved, cutting tools now use half the material." The hydraulic plant is tightening its belt and carefully managing resources by maximizing efficiency at every step—literally "digging for potential" right at the cutting edge.
Category: Company News
Release date: 2021-05-19
"The processing method has been improved, cutting tools now use half the material." The hydraulic plant is tightening its belt and carefully managing resources by maximizing efficiency at every step—literally "digging for potential" right at the cutting edge. By fine-tuning the manufacturing process, they’ve managed to cut the cost of keyway milling cutters in half.
It turned out that the adjusting ring often damaged the milling cutter when machining the step edges, leading to increased production costs. In response, factory employees proposed a solution: reducing the center distance between the five holes in the adjusting ring and refining the part-machining process by moving the hole-drilling operation to a dedicated drilling machine. This change significantly cut tooling costs compared to the original milling method, resulting in a 50% reduction in expenses for keyway milling cutters. Additionally, when machining the part’s cover, uneven material hardness caused milling cutters to wear out rapidly—after just 3 to 5 parts, the tools were essentially unusable. To produce 100 parts, over 20 cutting tools were required, totaling nearly 3,000 yuan in tooling costs, which was both expensive and failed to meet the surface roughness specifications outlined in the design drawings. To address these challenges and reduce tooling expenses, the factory adopted a meticulous cost-control approach, carefully optimizing every aspect of the production process. As a result of these improvements, standard milling cutters were replaced with carbide-tipped tools, drastically lowering costs. Now, only two carbide cutters and three carbide inserts are needed for every 100 parts produced—a total cost of just over 300 yuan, or about one-tenth of the previous expense. Based on annual production of 1,000 parts, this streamlined approach translates into savings of more than 25,000 yuan on tooling costs alone. Moreover, the improved machining process ensures that the surface finish meets all design requirements, guaranteeing superior product quality.
Keywords: Xuangan Hydraulic Branch Factory Reduces Tool Costs, Adjusts Processes to Unlock Hidden Potential and Cut Consumption
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