Keys to Reducing Defects and Improving Efficiency in CNC Aerospace Manufacturing

In aerospace manufacturing, the need for precision and quality is utmost. Computer Numerical Control (CNC) machining is a cornerstone technology used in producing high precision components. There are several keys to reducing defects and improving efficiency in CNC aerospace manufacturing. Many of the machined aerospace parts being produced have tight tolerances, machined from high alloy steels, into complex shapes. Control of the manufacturing process can be challenging. Eliminating defects while maintaining or improving efficiency requires knowledge, experience, reliable equipment, and operational vigilance. At Intrex we implement several strategies that address both defect reduction and manufacturing efficiency.

Advanced CNC Technologies

One of the primary considerations in reducing and/or eliminating defects is having the proper equipment. In recent years CNC equipment builders have made tremendous gains in control technology and mechanical advancements. Intrex latest equipment purchases reflect both these major features which make possible machining components with higher precision and improved throughput times.

The latest generations of CNC machine tools can also incorporate adaptive controls, that can monitor and adjust machine feeds and speeds during cutting cycles. These machines can also accommodate in-process gaging, that measure and adjust size during cycle. The machines are also well suited for different levels of automation. All these features help reduce scrap and add to the overall efficiencies necessary for cost reduction.

Improvements in Cutting Tools

Another component for reducing defects and improving efficiency in CNC machining is using high-quality cutting tools. In aerospace, because of the elevated use of high alloy metals, tool wear and tool life must be constantly monitored. Different speeds and feeds must be applied to these cutting tools, to maximize cutting conditions and optimize tool life. There have been great strides made by tooling companies to match machine capabilities with cutting conditions, insuring optimization of the machining process. Education and knowledge of cutting tools is critical for achieving efficiency.

A machine tool feature being offered and utilized on later model CNC machines is tool gaging. It gives the machine the ability to measure tool wear during the production cycle, without operator intervention. The machine can measure the part with a touch-probe of laser and make the necessary tool wear adjustments. It records the offset values and can stop the machine for tool changeout all within the program. This feature along with the better tool life management helps reduce scrap.

Program Simulation

Many later model CNC machines have a graphic simulation feature. This feature allows the setup person/operator to run a new program through the controller in a simulation mode. The monitor simulates the machines programmed moves in a dry-cycle state, allowing the operator to view, and adjust  the program prior to the machine actually running the part. The simulation shows tool path, machine and part work-holding interference areas. This feature can part of the operator setup procedure and prevent potential crashes.

Lean Manufacturing

At Intrex Aerospace we are practitioners of Lean manufacturing. Lean is a production process based on a manufacturing philosphy of maximizing productivity while simultaneously minimizing waste within a manufacturing operation. Lean principles play a crucial role in our reducing defects and improving efficiencies. The focus is on eliminating waste in all forms, whether it be time, materials, or labor. In the context of CNC machining, lean strategies can be applied to streamline workflows, reduce setup times, and improve overall process flow.

Part of our Lean utilization is Value Stream Mapping (VSM). It identifies bottlenecks and inefficiencies in the production process. By analyzing each step of our process, from raw material handling to final inspection, we can identify areas where waste occurs and implement improvements.

Skilled Workforce

Even utilizing the latest CNC machines and tooling, the experience and skill of the workforce remains a critical factor in minimizing defects and enhancing production efficiency. Retaining a skilled workforce is a must. Key to successful workforce retention of CNC operators, programmers, and maintenance personnel is regular training. Regular training and upskilling of our personnel is essential to ensure that they are proficient in the latest technologies and industry best practices.

A culture of continuous improvement within the workforce helps to foster a mindset focused on defect reduction and improved efficiency. By engaging our operators in the problem-solving process and providing them with the necessary resources and knowledge, we create an environment that promotes innovation and drives down the occurrence of defects.

Conclusion

The reduction of defects and improving efficiency in CNC aerospace is multifaceted. By embracing technological advancements, improved tooling, process optimization, lean principles, and a skilled workforce, we achieve higher-quality standards, while we reduce waste, and improve our efficiencies, all necessary components for being competitive in the global aerospace market.

If you would like more information about Intrex Aerospace please click here.