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MASTERCLASS: SUSTAINABLE MACHINING

Sustainable machining is the finishing of competitively priced products, which meet the needs of customers and which give total quality in the product life cycle, gradually reducing environmental impact and raw material and energy use throughout the life cycle and in the production chain to a level than at least is in balance with the carrying capacity of the planet.

This Masterclass focuses on every company facing the problem of small batch production of diverse workpieces in a rapidly changing world. Each company has an economic, social and environmental responsibility in addition to the classic business elements of cost control, productivity and quality. In every machining company, sustainable business starts with sustainable machining.

INSIGHTS

For a manager, it is important you have a good understanding of the core indicators (costs, productivity, quality, output, environmental foot print) that determine the efficiency and sustainability of your business.

An insight into and understanding of key indicators that determine the ‘health condition’ of the company is a first important step. From this understanding, concrete and correct decisions can then be taken regarding the ‘pain points’ and how best to address them.

The core in every machining company is the machining processes and systems. The challenge is to manage your machining processes in a reliable, cost-efficient, productive way, with minimal energy consumption and environmentally damaging emissions from waste products. In addition to the actual machining process, of course, it is also important that your production organisation is efficient and how effectively your people contribute to your success as a company.

The aim is to facilitate knowledge sharing, networking and the demonstration of cost efficiency, productivity and continuous improvement trends, technology and innovations.

 

 

This Masterclass focuses on managing directors, operations managers, heads of production, plant managers, manufacturing managers, engineering managers, senior engineers etc. who want to understand and control the key indicators that are defining and guiding a sustainable machining process and system; as well economical, human and environmental sustainability.

NEXT STEP production concept.

  • Industry4.0 model and NEXT STEP concept
  • Sustainable machining, why, how and what?
  • Sustainable pricing, why, how and what?

Production systems

  • HMLV-type machining production (production of small batches or single products), challenges and solutions
  • Cost control and time spent, how to optimize?
  • Sustainable production organisation, what is important?

Resource-efficient machining systems and processes

  • Description and comparison of different process and system settings
  • Group technology, standardisation and rationalisation

Sustainable machining process principles

  • Steering elements in a machining process
  • Variables in a machining process
  • Total quality definition, trade offs

The human factor

  • Role and mission of people
  • Knowledge, insight and skills to ensure, monitor and adjust a reliable and sustainable machining process
  • Mindset (KPI management and leadership)

Total production economy

  • Definition of the overall production economy
  • Description of fully integrated model (including hidden costs) with the 5 KPIs: cost control, productivity, quality assurance, total revenue and environmental impact.
  • In addition to the CPR factor (Cost Performance Ratio) set out in the ”economic or productive machining’ methodology, the EIPR (Environment Impact Performance Ratio), which, for example, charts the impact of dry/wet machining, is also important.

Description of the reliable and predictable machining process

  • Reliable and sustainable machining process, total quality
  • Tool wear and tool life
  • Practical process optimization through costs, productivity, quality, waste streams and energetic impact.

Full background information and reference can be found in the books Knowledge, Skills and Insight makes sustainable Machining; Applied Metal Cutting Physics, Best Practice; Global Tool Deterioration, Best Practice and other STEP technical publications.

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