Lead time is crucial in any engineering solution. Reducing lead time will significantly accelerate the overarching NPD goals. In any engineering project, we aim to reduce lead time by sticking to the deadline. Sometimes, by applying a better solution, we can quicken the process. That’s when experience comes to play.
In every project I tackle, my primary aim is to minimize lead time without sacrificing quality. Sticking to deadlines is crucial, but it’s not just about meeting dates. Often, finding a more effective solution can help speed the process along. This is where deep experience and expertise really make a difference.
I’d like to share a personal experience from a contract manufacturing project I worked on for a semiconductor equipment manufacturer, which illustrates the significant impact of reducing lead times.
Application - Semiconductor Manufacturing machine
Complex flange bending in alumium 1100
The project involved complex flange bending in aluminum 1100, requiring a sheet thickness that is only 50% of the required bending length. This presented a significant challenge in the bending process
Specific challenges with Aluminum 1100
Aluminum 1100 Properties: This grade of aluminum is known for its excellent corrosion resistance, high ductility, and good formability. However, it is relatively soft and prone to work hardening, making precise control necessary
- Sheet Thickness Relative to Bending Length: When the sheet thickness is only 50% of the required bending length, it introduces additional complexities:
- Risk of Buckling: Thin sheets are more prone to buckling or warping during bending.
- Control of Deformation: Ensuring uniform deformation across the bend can be challenging, as thinner materials may not distribute strain evenly.
- Tooling Requirements: Special care is needed in selecting the correct tooling to apply uniform force across the bend without causing damage.
This project required bending a 2mm thick aluminum sheet into a 4mm bend, which was initially deemed impossible. Typically, a basic bending operation needs a bend radius at least 6 times the sheet thickness. Meeting these requirements would necessitate specialized tooling, increasing lead time and costing over $1400.
To avoid these additional costs and delays, we modified the design to use a bending length 6 times the sheet thickness. The excess length was then milled and polished using a CNC machine. This approach allowed us to complete the operation within budget and on schedule, delivering world-class quality without extended lead times.
AUTHOR
Saravanan Kottieswaran
Assistant Manager Manufacturing, Srushty Global Solutions
As a Mechanical Engineer with extensive expertise in Vendor management, metal fabrication, CNC machining, and injection molding, he brings a wealth of expertise in overseeing production processes, optimizing workflow efficiency, and ensuring high-quality output. His dedication to building strong client relationships and passion for innovation and continuous improvement in manufacturing techniques make them an invaluable asset to our team.