How to balance cost control and efficiency of precision machining under the small batch customized production mode?
Publish Time: 2024-12-16
At the moment of diversified development of manufacturing industry, the small batch customized production mode is increasingly popular. Precision machining enterprises are facing the severe challenge of meeting personalized needs while taking into account cost and efficiency. The key to breaking the deadlock lies in precise policy implementation and coordinated optimization.
Flexible machining equipment selection is the cornerstone. Although the initial investment is high, CNC machine tools with fast mold change and multi-program storage switching functions can instantly adjust machining parameters according to different customized workpieces, reduce equipment idleness, and dilute the depreciation cost of single equipment. For example, the five-axis linkage machining center can complete complex multi-faceted machining in one clamping, greatly shortening the process flow time and improving overall efficiency.
Simplification of process planning is the core strategy. Engineers use simulation software to simulate machining paths, delete redundant processes, and merge similar machining steps; for small batches, they abandon complex special fixtures and use multi-functional universal fixtures with zero-point positioning systems. Machining of multiple parts can be completed in one clamping, reducing fixture costs, while reducing workpiece positioning errors and accelerating the machining process.
Tool and consumables management should not be underestimated. Analyze the order material combination, centrally purchase high-performance tools with strong versatility and durability, and negotiate small batch discounts with suppliers; introduce tool life monitoring systems, change tools in time, avoid excessive wear and scrapping of workpieces, ensure machining continuity, and reduce the cost of each unit.
Human resource allocation is the key to increasing efficiency. Cultivate multi-skilled and compound technicians who can flexibly switch between programming, operation, and quality inspection positions, dynamically assign tasks according to the urgency of orders, operate multiple machines by one person, and fully tap human potential; for complex customized processes, organize expert groups to tackle special problems to prevent delays in construction due to technical problems and ensure delivery timeliness.
Digital management is the driving force behind the scenes. The introduction of enterprise resource planning (ERP) and manufacturing execution system (MES) allows real-time tracking of order progress, material inventory, and equipment status, accurate production scheduling, and avoidance of material backlogs or out-of-stock shutdowns. Machining data is collected to review cost structures and efficiency bottlenecks, providing a basis for continuous optimization of subsequent orders, making small-batch customization in the field of precision machining cost-controllable and efficiency-enhancing, in line with the changing market demands.
