In the sheet metal processing industry, small-scale production often faces the dilemma of “high cost per piece and low efficiency”. How to achieve cost optimization within a limited order quantity? This article reveals practical money saving techniques from the two core aspects of material layout and process selection.
I、 Cost Control in the Material Scheduling Stage
- Optimization of nesting software to improve material utilization rate
Traditional manual cutting often results in 15% -20% material waste. After introducing professional nesting software such as FastCAM and SinoCAM, the material utilization rate can be increased to over 85% through intelligent algorithms. Taking 2mm thick cold-rolled steel plate as an example, for every 5% increase in utilization rate, each plate can produce 2-3 more parts, resulting in significant long-term cost savings.
- Reasonably select material specifications
When producing in small batches, the closest standard sheet size should be selected based on the part size. For example, if the part size is 400 × 300mm, the utilization rate of selecting a 1200 × 800mm whole sheet is much higher than using a 1000 × 1000mm specification. **The core principle of small batch material discharge is’ material measurement and regulation ‘.
- Matching the discharge direction with the material texture
For materials with directional requirements (such as galvanized sheet and aluminum zinc coated sheet), the direction of the parts should be unified when discharging to avoid processing waste caused by flipping. Meanwhile, considering the influence of material rolling direction on bending performance, reasonable material discharge can reduce the scrap rate.
2、 Cost saving strategies in the process selection stage
- Simplify molds and reduce tooling costs
Small batch production should avoid using specialized molds. Universal mold combinations or simple forming fixtures can be prioritized, reducing tooling costs by 60% -80%. For bent parts, adjusting the design angle can reduce the number of mold changes and improve processing efficiency.
- Merge processes to reduce clamping frequency
Reducing the number of clamping times of workpieces on the machine tool can not only shorten processing time, but also reduce positioning errors. It is recommended to consider the possibility of merging processes during the design phase, such as combining punching and cutting into one processing to reduce turnover costs.
- Principle of proximity for surface treatment
Choosing local suppliers for surface treatment such as powder coating and galvanizing can significantly reduce transportation costs. At the same time, choosing a reasonable pre-treatment process (such as the board’s built-in coating) can simplify the post-processing process.
3、 Comprehensive cost saving suggestions
Design standardization: Try to use standard hole positions and bending angles as much as possible to reduce non-standard customization
Batch merging and accepting orders: multiple similar parts are merged and arranged to improve material utilization
Establishing long-term cooperation with suppliers: Small batch customers often have weak bargaining power, and long-term cooperation can obtain more favorable prices
Conclusion: Cost control in small-scale production of sheet metal is a systematic project. From scientific planning of material scheduling to precise decision-making of process selection, optimizing each link can bring considerable benefits. Saving money is not about lowering quality, but about spending every penny wisely.
Metalstar looks forward to collaborating with you!