Global Tool Deterioration Analysis

Jun 12, 2018

Global Tool Deteriation Analysis (GTDA)

Nowadays every manufacturing plant understands the value of Industry4.0 principles for improving the overall efficiency of the company. Successful implementation of Industry4.0 is supported by two main pillars; first operational excellence and second applying the possibilities of modern digitalisation techniques in an intelligent way.

To reach the highest possible operational excellence, 3 goals need to be achieved: eliminating or reducing waste (lean manufacturing principles), minimising inflexibility (theory of constraints), and minimising variability (Six Sigma thinking).

Seco developed a more complete and practical approach, we call it the NEXT STEP production model, and added some elements to the equation. NEXT STEP production includes being in full control of the machining process, fully understand the influence of the workpiece materials on the machining process, assure a reduced waste of resources (lean, constraints and 6Sigma thinking), use production economy and first time yield (FTY) as effective measuring tools (KPI’s) and last but not least, support all by a well working people leadership model (the machinist culture is rather typical!). The thinking behind this model is that the efficiency of a manufacturing plant truly is determined by ‘bottle necks’ in the manufacturing environment and system. The slowest process determines the speed of the total, however fast the others are!

Tool wear analysis is traditionally a technique used to evaluate the functioning of a cutting tool by means of evaluating wear patterns on used tools. In the basic approach it serves the purpose of optimising the tool selection and the cutting conditions for the application at hand. And as such it serves a rather narrow purpose, namely optimise the cutting tool and to some extend the machining process.

Over time we realised that there are however much more gaining’s to take out of this analysis. In a broader setting we refer to it as a Global Tool Deterioration Analysis (GTDA).

What are the main advantages? Tools cost money and by linking the results of a GTDA to e.g. an analysis of COGS, we can quantify the impact of tooling cost on the total costs more precise. Tool manipulation cost time and adding SMED analysis to a GTDA will learn how big the impact of tool manipulation really is. The usage of tools has for sure an impact on the OEE of the plant and on the system efficiency (VSM techniques will reveal how the tools contribute or counteract). E.g. when the system efficiency is low, optimising tools will have only an arbitrary effect. But when system efficiency is high, making sure that tools function in a very reliable way is crucial. However, with whatever system efficiency, a non-functioning tool (e.g. because it is broken) will create a big bottleneck in the system and destroy the system efficiency.

Seco’s GTDA is a profound analysis of used cutting tools. The results of this analysis are linked to e.g. COGS, OEE, SMED analysis, system efficiency (VSM) to determine the real and total impact of cutting tools on the total manufacturing system (technical and economical). The results are the basis on which a number of simulations are done to see how certain actions would influence the different technical and economical KPI’s of the manufacturing plant. A GTDA is concluded with an overview of strengths, improvement possibilities, and improvement levers. And of course a proposal for concrete actions to implement.

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