Improving machining efficiency >30% in China

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Hands-on training of Chinese directors in Finland and Chinese machine operators in China

 Win-win to all stakeholders - The end customer, SabriScan and the Chinese mould maker

Background
​Sabriscan had a well function cooperation with a mould manufacturing network partner in China. However, the tool prices to certain OEM customers in Europe were >30% too high. The lead times as well were >3 weeks too long.

The client was very price sensitive and it was a must win battle to find remedies for inefficiency. Sabriscan had a solution.

Solution
Sabriscan applied it's machining training package to transfer critical improvements in machining to its Chinese partner. 

The scope included production planning, CAD-design, CAM-programming, work shop oriented programming, optimal parameters, problem solving, EDM free machining, 3+2 axis machining, super precision finishing, polishing, heavy roughing, Lean, leadership culture and people management.

The training was arranged in practical hands-on fashion. The first part of the training was done in Finland and the second part in China. 

Benefit to customer
The key benefits covered wide range of topics in machining resulting in >30% cost improvements and shorter lead times:

• 10 EDM stages were replaced by 2 stages in direct machining, 80% of electrodes not needed at all --> 1 machine instead of 2-3 machines, 4-7 people less. Clear impact to costs and delivery time
• Replacing over-long tools --> reduced vibration, improved cutting parameters, better surface quality, getting rid of unnecessary  EDM-use
• Job rotation introduced in programming and machining, operators started to make CAM-programs (previously forbidden) --> no more bottle necks, improved problem solving and comprehensive understanding of the shop floor
• Introducing new tooling progress report --> professional rigorous way to follow-up the project and to stay on critical path

Replacing over-long tools was a simple, yet one of the high impact improvements in the production of Sabriscan's Chinese partner

Replacing EDM with direct machining was another efficient way to boost up productivity