PRODUCTIVITY & COST ANALYSIS

Transcription

1 SERVICES & SOLUTIONS PRODUCTIVITY COST ANALYSIS HOW IS IT DONE? PRODUCTIVITY & COST ANALYSIS By benchmarking the current process, we can identify where the greatest savings can be achieved. Once we have the benchmark data, we can begin to apply our extensive experience within the global metalcutting industry to create an optimized operation to suit the manufacturing environment. Follow Seco Tools on Twitter, Facebook, LinkedIn and YouTube and stay up to date on new products and technology, special events, trade shows, special promotions and more. THE STAGES OF PCA Cutting Edge Conversation Blog: cuttingedgeconversation.blogspot.com/ CURRENT METHOD BENCHMARK PRODUCTIVITY INITIAL CHANGE CONVERSION METHOD REVIEW PROCESS IMPROVEMENT COSTS Product videos: LONG TERM METHOD CONTINUOUS IMPROVEMENT Every Technical Specialist has the knowledge and tools to conduct a detailed review. Contact your Seco Technical Specialist to set up an appointment for a complete review of your process. Determine cutting conditions speed feed depth of cut Evaluate current tooling review geometry grade Understand the process cycle time through-put requirements No significant process change Convert competitive items Review cutting conditions catalog data apply experience Change cutting conditions longer tool life increased through put reduced cycle time To find an Authorized SECO Distributor near you, please refer to the Distributor Locator on our website: The re-process stage different tooling approach combine operations more aggressive cutting conditions increase productivity, lower costs Can also do What If modeling higher available spindle speeds more rigidity higher horsepower For technical assistance, call: CUTTING COSTS & INCREASING PRODUCTIVITY 2805 Bellingham Drive, Troy, MI P Copyright 2012 Seco Tools Inc. GT Printed in USA. All rights reserved.

2 WHAT IS PCA? FASTER & MORE INVOLVED With Seco s Productivity Cost Analysis, we look at the entire manufacturing process, not just the cutting tools, to see where costs can be reduced and productivity can be increased. The tools are a small part of the total cost, but can have a significant impact on the profitability of the overall process. Performed by a qualified Seco representative, Seco s PCA evaluates all types of tools and technologies used in a process to generate a comprehensive report that includes both process information, such as tooling and cutting data, and cost information, encompassing cost per part, output per hour and investment cost. Customers who use Seco s PCA can typically expect to benefit from total cost savings of up to 30% and productivity increases of up to 40%, regardless of the industry sector that they are working in. COST BREAKDOWN FOR AN AVERAGE MACHINING OPERATION Cost saving from reducing tool price Cost saving from improving productivity with PCA 17% 27% 22% Total savings - 3% 39% Labor 7%Tooling Total savings 15% - 30% Using PCA, we can evaluate operations ranging from a single machine tool process, to the complete path a workpiece takes on its journey through a manufacturing plant. The focus is on productivity improvements that have the largest impact on the toal cost. This process takes bottlenecks or constraint operations into consideration, where more in-depth studies are necessary. The PCA software provides a comprehensive report with both process information, such as tooling and cutting data, and cost information such as cost per part, output per hour, tool consumption and investment cost. VARIABLE COSTS CUTTING TOOL WORKPIECE MATERIAL FIXED COSTS MACHINERY LABOR BLDG & ADMIN COST PER PART SAVINGS SCENARIO A SCENARIO B SCENARIO C TODAY 30% DISCOUNT 50% TOOL LIFE INCREASE CUTTING SPEED INCREASE $.30 $.21 $.20 $.45 $2.16 $2.48 $1.76 $10.00 $9.91 $9.90 $ % For faster implementation in projects of sufficient scope, Seco offers a PITCREW approach to the task. The PITCREW approach is a structured way to reach your continuous improvement targets. It is a commitment from both Seco and the customer. P I T C R E W Process Review process Improvement Agree on goals and priorities Team Work together Cost Evaluate manufacturing cost Reduction Focus on cycle time and cost per part Efficiency Focus on bottleneck operations Winning Solutions Global Seco solutions Seco will commit the technical resources and asks the customer to provide: Access to the shop Programming support Regular meetings to establish priorities Commitment for a long term partnership Seco s PCA software provides detailed reports to document and review savings, cycle time and costs. These reports provide the detail required to evaluate either the potential savings realized from a simple insert change, or the return on investment for a more complex change to the process that will require new durable tools. The payback calculation is simple and allows you predict the tooling and manufacturing cost per unit for any component part. This team will be able to review and benchmark the entire process and quickly begin to work on bottleneck operations. CUSTOMER SUCCESS 14% 3%Tooling 3 Labor REPORTING Seco has also developed software to track and document active and closed projects. The key to successful implementation is close cooperation and communication between the Seco PITCREW team and the customer. The tooling champion from the customer will establish the overall objectives and project priorities. Under his direction, the PITCREW team goes to work to improve the manufacturing process or cost position based on the project objective. The chart below helps to summarize the projects, keep the most important projects on track and document the savings. This system has worked at hundreds of customers around the world. Stryker Orthopaedics saw a significant improvement with the help and support of Seco Tools and PCA. ANY CUSTOMER ANYWHERE STRYKER ORTHOPAEDICS Stryker Orthopaedics is a worldwide leader in the medical device industry offering an unparalleled variety of high quality, innovative products and services. At the Stryker Orthopaedics site in Cork, Ireland, different parts for medical use are manufactured. Stryker was experiencing some difficulties in the production of titanium hip cups. By using Seco PCA to analyze costs and applying the latest in tooling technology and extensive metal cutting knowledge, Seco was able to make substantial improvements both in terms of cost and increased output. On a particular project within one of our manufacturing cells, we managed to reduce the cost per part by 32% and we also increased our throughput by approximately. We were so successful at that manufacturing cell that we decided to roll out the process across the factory. Melvin Hartnett Manufacturing Technologist Stryker Orthopaedics A Seco representative presents the detailed analysis, which takes into account a great many factors, including batch sizes, machining data, hourly rates, purchase costs, shift patterns and business plans. All these factors have an influence on the effectiveness of the Seco s PCA system, as it is used to drive down costs and improve productivity. Hip Cap Costs WE CARE MORE ABOUT YOUR MANUFACTURING SOLUTIONS PCA is Productivity Cost Analysis. It is software that we use in the field and in our own production units to analyze component cost by operation. It allows us to analyze the complete process so we can focus on high cost operations that if improved, can have a significant impact on the overall cost and through-put. To date, Seco has carried out thousands of PCA analyses worldwide, which have resulted in substantial savings for the companies involved Use the Seco technical resources and Seco products to improve your manufacturing processes and we both win.

3 SERVICES & SOLUTIONS PRODUCTIVITY COST ANALYSIS HOW IS IT DONE? PRODUCTIVITY & COST ANALYSIS By benchmarking the current process, we can identify where the greatest savings can be achieved. Once we have the benchmark data, we can begin to apply our extensive experience within our global metalcutting organization to create an optimized solution to suit the manufacturing environment. Follow Seco Tools on Twitter, Facebook, LinkedIn and YouTube and stay up to date on new products and technology, special events, trade shows, special promotions and more. THE STAGES OF PCA Cutting Edge Conversation Blog: cuttingedgeconversation.blogspot.com/ CURRENT METHOD BENCHMARK PRODUCTIVITY INITIAL CHANGE CONVERSION METHOD REVIEW PROCESS IMPROVEMENT COSTS Product videos: LONG TERM METHOD CONTINUOUS IMPROVEMENT Every Technical Specialist has the knowledge and tools to conduct a detailed review. Contact your Seco Technical Specialist to set up an appointment for a complete review of your process. Determine cutting conditions speed feed depth of cut Evaluate current tooling review geometry grade Understand the process cycle time through-put requirements No significant process change Convert competitive items Review cutting conditions catalog data apply experience Change cutting conditions longer tool life increased through put reduced cycle time To find an Authorized SECO Distributor near you, please refer to the Distributor Locator on our website: The re-process stage different tooling approach combine operations more aggressive cutting conditions increase productivity, lower costs Can also do What If modeling higher available spindle speeds more rigidity higher horsepower For technical assistance, call: CUTTING COSTS & INCREASING PRODUCTIVITY 2805 Bellingham Drive, Troy, MI P Copyright 2012 Seco Tools Inc. GT Printed in USA. All rights reserved.

4 WHAT IS PCA? FASTER & MORE INVOLVED With Seco s Productivity Cost Analysis, we look at the entire manufacturing process, not just the cutting tools, to see where costs can be reduced and productivity can be increased. The tools are a small part of the total cost, but can have a significant impact on the profitability of the overall process. Performed by a qualified Seco representative, Seco s PCA evaluates all types of tools and technologies used in a process to generate a comprehensive report that includes both process information, such as tooling and cutting data, and cost information, encompassing cost per part, output per hour and investment cost. Customers who use Seco s PCA can typically expect to benefit from total cost savings of up to 30% and productivity increases of up to 40%, regardless of the industry sector that they are working in. COST BREAKDOWN FOR AN AVERAGE MACHINING OPERATION Cost saving from reducing tool price Cost saving from improving productivity with PCA 17% 27% 22% Total savings - 3% 39% Labor 7%Tooling Total savings 15% - 30% Using PCA, we can evaluate operations ranging from a single machine tool process, to the complete path a workpiece takes on its journey through a manufacturing plant. The focus is on productivity improvements that have the largest impact on the toal cost. This process takes bottlenecks or constraint operations into consideration, where more in-depth studies are necessary. The PCA software provides a comprehensive report with both process information, such as tooling and cutting data, and cost information such as cost per part, output per hour, tool consumption and investment cost. VARIABLE COSTS CUTTING TOOL WORKPIECE MATERIAL FIXED COSTS MACHINERY LABOR BLDG & ADMIN COST PER PART SAVINGS SCENARIO A SCENARIO B SCENARIO C TODAY 30% DISCOUNT 50% TOOL LIFE INCREASE CUTTING SPEED INCREASE $.30 $.21 $.20 $.45 $2.16 $2.48 $1.76 $10.00 $9.91 $9.90 $ % For faster implementation in projects of sufficient scope, Seco offers a PITCREW approach to the task. The PITCREW approach is a structured way to reach your continuous improvement targets. It is a commitment from both Seco and the customer. P I T C R E W Process Review process Improvement Agree on goals and priorities Team Work together Cost Evaluate manufacturing cost Reduction Focus on cycle time and cost per part Efficiency Focus on bottleneck operations Winning Solutions Global Seco solutions Seco will commit the technical resources and asks the customer to provide: Access to the shop Programming support Regular meetings to establish priorities Commitment for a long term partnership Seco s PCA software provides detailed reports to document and review savings, cycle time and costs. These reports provide the detail required to evaluate either the potential savings realized from a simple insert change, or the return on investment for a more complex change to the process that will require new durable tools. The payback calculation is simple and allows you predict the tooling and manufacturing cost per unit for any component part. This team will be able to review and benchmark the entire process and quickly begin to work on bottleneck operations. SUCCESS 14% 3%Tooling 3 Labor REPORTING Seco has also developed software to track and document active and closed projects. The key to successful implementation is close cooperation and communication between the Seco PITCREW team and the customer. The tooling champion from the customer will establish the overall objectives and project priorities. Under his direction, the PITCREW team goes to work to improve the manufacturing process or cost position based on the project objective. The chart below helps to summarize the projects, keep the most important projects on track and document the savings. This system has worked at hundreds of customers around the world. Stryker Orthopaedics saw a significant improvement with the help and support of Seco Tools and PCA. ANY CUSTOMER ANYWHERE STRYKER ORTHOPAEDICS Stryker Orthopaedics is a worldwide leader in the medical device industry offering an unparalleled variety of high quality, innovative products and services. At the Stryker Orthopaedics site in Cork, Ireland, different parts for medical use are manufactured. Stryker was experiencing some difficulties in the production of titanium hip cups. By using Seco PCA to analyze costs and applying the latest in tooling technology and extensive metal cutting knowledge, Seco was able to make substantial improvements both in terms of cost and increased output. On a particular project within one of our manufacturing cells, we managed to reduce the cost per part by 32% and we also increased our throughput by approximately. We were so successful at that manufacturing cell that we decided to roll out the process across the factory. Melvin Hartnett Manufacturing Technologist Stryker Orthopaedics A Seco representative presents the detailed analysis, which takes into account a great many factors, including batch sizes, machining data, hourly rates, purchase costs, shift patterns and business plans. All these factors have an influence on the effectiveness of the Seco s PCA system, as it is used to drive down costs and improve productivity. Hip Cap Costs WE CARE MORE ABOUT YOUR MANUFACTURING SOLUTIONS PCA is Productivity Cost Analysis. It is software that we use in the field and in our own production units to analyze component cost by operation. It allows us to analyze the complete process so we can focus on high cost operations that if improved, can have a significant impact on the overall cost and through-put. To date, Seco has carried out thousands of PCA analyses worldwide, which have resulted in substantial savings for the companies involved Use the Seco technical resources and Seco products to improve your manufacturing processes and we both win.

5 WHAT IS PCA? FASTER & MORE INVOLVED With Seco s Productivity Cost Analysis, we look at the entire manufacturing process, not just the cutting tools, to see where costs can be reduced and productivity can be increased. The tools are a small part of the total cost, but can have a significant impact on the profitability of the overall process. Performed by a qualified Seco representative, Seco s PCA evaluates all types of tools and technologies used in a process to generate a comprehensive report that includes both process information, such as tooling and cutting data, and cost information, encompassing cost per part, output per hour and investment cost. Customers who use Seco s PCA can typically expect to benefit from total cost savings of up to 30% and productivity increases of up to 40%, regardless of the industry sector that they are working in. COST BREAKDOWN FOR AN AVERAGE MACHINING OPERATION Cost saving from reducing tool price Cost saving from improving productivity with PCA 17% 27% 22% Total savings - 3% 39% Labor 7%Tooling Total savings 15% - 30% Using PCA, we can evaluate operations ranging from a single machine tool process, to the complete path a workpiece takes on its journey through a manufacturing plant. The focus is on productivity improvements that have the largest impact on the toal cost. This process takes bottlenecks or constraint operations into consideration, where more in-depth studies are necessary. The PCA software provides a comprehensive report with both process information, such as tooling and cutting data, and cost information such as cost per part, output per hour, tool consumption and investment cost. VARIABLE COSTS CUTTING TOOL WORKPIECE MATERIAL FIXED COSTS MACHINERY LABOR BLDG & ADMIN COST PER PART SAVINGS SCENARIO A SCENARIO B SCENARIO C TODAY 30% DISCOUNT 50% TOOL LIFE INCREASE CUTTING SPEED INCREASE $.30 $.21 $.20 $.45 $2.16 $2.48 $1.76 $10.00 $9.91 $9.90 $ % For faster implementation in projects of sufficient scope, Seco offers a PITCREW approach to the task. The PITCREW approach is a structured way to reach your continuous improvement targets. It is a commitment from both Seco and the customer. P I T C R E W Process Review process Improvement Agree on goals and priorities Team Work together Cost Evaluate manufacturing cost Reduction Focus on cycle time and cost per part Efficiency Focus on bottleneck operations Winning Solutions Global Seco solutions Seco will commit the technical resources and asks the customer to provide: Access to the shop Programming support Regular meetings to establish priorities Commitment for a long term partnership Seco s PCA software provides detailed reports to document and review savings, cycle time and costs. These reports provide the detail required to evaluate either the potential savings realized from a simple insert change, or the return on investment for a more complex change to the process that will require new durable tools. The payback calculation is simple and allows you predict the tooling and manufacturing cost per unit for any component part. This team will be able to review and benchmark the entire process and quickly begin to work on bottleneck operations. SUCCESS 14% 3%Tooling 3 Labor REPORTING Seco has also developed software to track and document active and closed projects. The key to successful implementation is close cooperation and communication between the Seco PITCREW team and the customer. The tooling champion from the customer will establish the overall objectives and project priorities. Under his direction, the PITCREW team goes to work to improve the manufacturing process or cost position based on the project objective. The chart below helps to summarize the projects, keep the most important projects on track and document the savings. This system has worked at hundreds of customers around the world. Stryker Orthopaedics saw a significant improvement with the help and support of Seco Tools and PCA. ANY CUSTOMER ANYWHERE STRYKER ORTHOPAEDICS Stryker Orthopaedics is a worldwide leader in the medical device industry offering an unparalleled variety of high quality, innovative products and services. At the Stryker Orthopaedics site in Cork, Ireland, different parts for medical use are manufactured. Stryker was experiencing some difficulties in the production of titanium hip cups. By using Seco PCA to analyze costs and applying the latest in tooling technology and extensive metal cutting knowledge, Seco was able to make substantial improvements both in terms of cost and increased output. On a particular project within one of our manufacturing cells, we managed to reduce the cost per part by 32% and we also increased our throughput by approximately. We were so successful at that manufacturing cell that we decided to roll out the process across the factory. Melvin Hartnett Manufacturing Technologist Stryker Orthopaedics A Seco representative presents the detailed analysis, which takes into account a great many factors, including batch sizes, machining data, hourly rates, purchase costs, shift patterns and business plans. All these factors have an influence on the effectiveness of the Seco s PCA system, as it is used to drive down costs and improve productivity. Hip Cap Costs WE CARE MORE ABOUT YOUR MANUFACTURING SOLUTIONS PCA is Productivity Cost Analysis. It is software that we use in the field and in our own production units to analyze component cost by operation. It allows us to analyze the complete process so we can focus on high cost operations that if improved, can have a significant impact on the overall cost and through-put. To date, Seco has carried out thousands of PCA analyses worldwide, which have resulted in substantial savings for the companies involved Use the Seco technical resources and Seco products to improve your manufacturing processes and we both win.

6 SERVICES & SOLUTIONS PRODUCTIVITY COST ANALYSIS HOW IS IT DONE? PRODUCTIVITY & COST ANALYSIS By benchmarking the current process, we can identify where the greatest savings can be achieved. Once we have the benchmark data, we can begin to apply our extensive experience within the global metalcutting industry to create an optimized operation to suit the manufacturing environment. Follow Seco Tools on Twitter, Facebook, LinkedIn and YouTube and stay up to date on new products and technology, special events, trade shows, special promotions and more. THE STAGES OF PCA Cutting Edge Conversation Blog: cuttingedgeconversation.blogspot.com/ CURRENT METHOD BENCHMARK PRODUCTIVITY INITIAL CHANGE CONVERSION METHOD REVIEW PROCESS IMPROVEMENT COSTS Product videos: LONG TERM METHOD CONTINUOUS IMPROVEMENT Every Technical Specialist has the knowledge and tools to conduct a detailed review. Contact your Seco Technical Specialist to set up an appointment for a complete review of your process. Determine cutting conditions speed feed depth of cut Evaluate current tooling review geometry grade Understand the process cycle time through-put requirements No significant process change Convert competitive items Review cutting conditions catalog data apply experience Change cutting conditions longer tool life increased through put reduced cycle time To find an Authorized SECO Distributor near you, please refer to the Distributor Locator on our website: The re-process stage different tooling approach combine operations more aggressive cutting conditions increase productivity, lower costs Can also do What If modeling higher available spindle speeds more rigidity higher horsepower For technical assistance, call: CUTTING COSTS & INCREASING PRODUCTIVITY 2805 Bellingham Drive, Troy, MI P Copyright 2012 Seco Tools Inc. GT Printed in USA. All rights reserved.