In manufacturing, throughput is everything.

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There are many approaches to production machining. Sometimes what used to work for us simply doesn't cut it any more. As we see advancements in hardware and software tools, our old methods reach obsolescence and an overhaul is required.  In these 3 case studies, we examine 3 scenarios where customers reached out to us to help them revamp their processes and increase the throughput on their production runs.

Case Study #1

A medical OEM in the SF Bay Area was running a part as follows:

• Machine: Haas 3-axis vertical mill
• Operations per part: 4
• Part density: 1 per machine
• Cycle time: 45 minutes
• Parts per 24 hour cycle: 16

Although this company was running this part on a vertical mill, they did have a Mazak horizontal available. We completely rehauled the process for the horizontal as follows:

• Machine: Mazak Mazatech FH-6800 
• Operations per part: 2
• Part density: 8 per machine
• Cycle time: 25 minutes
• Parts per 24 hour cycle: 36

By switching to a horizontal mill, redesigning the fixturing and using high quality cutting tools we were able to eliminate two operations, increase the part density 8x, cut the cycle time by 44% and enable them to run a full pallet of 8 parts lights-out! The end result is a 125% increase in throughput.

Case Study #2

A firearms manufacturer in Utah invested in a Matsuura MX-330 PC10, bringing Zappettini Consulting on board to make it a turnkey operation. The result was 10 pallets, 4 parts per pallet, for a total of 40 parts per machine cycle. In addition to simplifying the process for the customer, we were able to increase machine utilization, improve their cycle times, and for the first time in the company's history, provide them with lights-out manufacturing from Friday to Sunday. 

The client realized a 50% increase in throughput, from 1000 parts per month to 1500 parts per month.

Case Study #3

The same medical OEM in the SF Bay Area was running a part as follows:

• Machine: Mazak Mazatech FH-6800 
• Operations per part: 2
• Part density: 8 per machine
• Cycle time: 85 minutes
• Parts per 24 hour cycle: 16

This time we kept the part on the same machine they were already using. Still, through the use of more efficient tool paths, better cutting tools and improved custom workholding we were able to deliver the following results:

• Machine: Mazak Mazatech FH-6800 
• Operations per part: 2
• Part density: 8 per machine
• Cycle time: 53 minutes
• Parts per 24 hour cycle: 24

Big changes in results don't always require big changes in the process. Simply by using high quality tools with a thoughtful setup, our client saw a 50% increase in throughput.