Small changes to the manufacturing process can deliver significant improvements in cost, efficiency and yield. At Accura Engineering, a recent review of material usage and machining processes revealed an opportunity to improve three products supplied as part of a single kit.
By analysing our material stock sizes, we found that we could manufacture two parts from a single stock bar rather than one. This significantly increased material yield and reduced the machining time, as well as the amount of raw material required.
Designing a Fixture Around Efficiency
To take advantage of this opportunity, our engineering team developed a new fixture around three key objectives: reducing material scrap, improving accuracy and repeatability, and shortening loading times.
The new fixture uses each stock bar more efficiently and allows the team to position and machine the parts more effectively. By reducing unnecessary material waste and simplifying the loading process, we increased yield while reducing machining time.
The Result
The trial batches demonstrated a significant improvement over the previous manufacturing method.
By optimising how we allocated the material and introducing the new fixture, we achieved:
- 50% reduction in raw material costs
- 1 hour reduction in machining time
- 100% pass rate across the trial batches
- Improved material yield from the same stock allocation
The improvement shows that reducing cost and lead time does not have to compromise quality. By combining detailed process analysis with practical engineering improvements, we made better use of existing material, reduced machining requirements and maintained complete confidence in the finished components.
How This Benefits Our Customers
For customers, these improvements create a more cost-effective and dependable supply route. Lower raw material costs and reduced machining time help keep component pricing competitive, while the improved fixture supports consistent quality across repeat production runs.
Shorter machining times can also support faster turnaround, giving customers greater confidence when they need reliable delivery schedules or repeat batches. By improving efficiency without affecting quality, Accura Engineering helps customers reduce overall production risk while maintaining the standards required for precision-engineered components.
Engineering Efficiency Into The Process
The project highlights the value of looking beyond individual machining operations and assessing the complete manufacturing process. From material selection and allocation through to fixturing and machining, each stage offers an opportunity to improve efficiency.
The project delivered a more efficient, repeatable manufacturing process that increases yield, reduces costs, and shortens production times while maintaining a 100% pass rate.
Sometimes, the biggest manufacturing improvements come from looking at the process differently.
Looking to reduce machining time, lower component costs, or improve repeat production efficiency? Speak to Accura Engineering about how smarter manufacturing processes can support your next project.
