5-Axis CNC machining reduces labor costs by enabling single-setup processing, increasing automation, enhancing precision, accelerating production speed, and minimizing human error.
Streamline Production Processes
Setup times for complex part manufacturing can be heavily impacted by the inclusion of 5-axis CNC machining in production processes. The ability to accommodate multiple sides of a part within one setup not only reduces the fabrication timeline, but lowers the per part labor costs typically associated with repeated setups, and machine down times.
Eliminates Multiple Setups on Complex Parts
5-axis CNC machinings One of the most powerful features 5-axis CNC machining has to offer is that it has the potential to execute complicated geometries in a single setup. Because traditional machining processes usually need the workpiece to be moved and repositioned a few times, so it is high effort and low precision. On the other hand, a 5-axis machine can pivot and rotate on more than one axis allowing for a 5-axis approach to harder to reach areas without the need of a human to move the workpeice. Using 5-axis technology reduced setup times for complex parts up to 75%, which means fewer hours of labor at significant cost afternoon the study of Machinery Marketing International.
Reduced Machine Idle Time
This idle time is dramatically reduced with 5-axis CNC machining. The non-stop working without need of placement is another factor that contributes to a higher success rate regarding machines cutting more and resting less. For example, aerospace components manufacturer reported that the integration of 5-axis machines in their production process led to an overall reduction of machine idle time by 30%, improving production efficiency, as well as the need to provide human resources to oversee and maintain operations during downtime.
Minimization of Human Errors
5-axis CNC machines are precise and fully automated which eliminates the chances of human errors to a great extent. The reduction in mistakes means less rework that usually requires extra labor and materials. One source found in an automotive parts production line reported a 40% reduction in production errors using machining within 5 axes; thus reducing labor and waste management costs.
Greater Production Flexibility
5-axis CNC machining offers better production scheduling and quick turn around times. This modularity provides manufacturers with the ability to respond more rapidly to shifts in production volume and without the capital investment or additional labor requirements. For a medical device manufacturer this wonderful technology allowed them to increase output by 20% before adding shifts and/or labor hours… so, a 10%-20% reduction in labor costs/unit produced, work that out for a six axis machine
Increase Automation
It helps reduce labor costs by enabling 5-axis CNC machining with built-in automation that drastically increases the level of automation in the manufacturing processes. The automation of highly intervention-required operations is very important in converting production floors into more efficient and non-labor-intensive environments.
Complex Machining Automation
A 5-axis CNC machine really shines at automating more complex tasks that would normally need multiple setups and manual resolution using traditional 3-axis equipment. This allows even complex aerospace components which must be manufactured using exact angles and curves to complete machining in a solitary operation without any repositioning of humans. This allows for faster production as well as a dramatically reduced number of labor hours required. In one example, several companies that switched to 5-Axis machines for parts that require machining on multiple faces saw a 50% reduction in manual efforts away from manipulating the part and tooling spring types.
Less Manual Supervision
A comprehensive set of test automations allows for decreased manual monitoring. The software of 5-axis cnc machines is quite complex and enables the control system of the machine to use this information to take corrective action, which happens in real-time. This change in control nature eliminates the need for the workforce. An industrial equipment manufacturer revealed that deploying 5-axis CNC machines reduce their direct supervisory labor by 30% since the machines required little human assistance and operated effectively with minimal intervention.
Enhanced Production Accuracy
Due to the high precision of 5-axis CNC machining are significantly less errors or defects that would require rework, which minimizes the amount of labor required for rework and quality control. Its high accuracy helps ensure products are to quality standards the first time around, which reduces waste and reprocessing. When a medical devices manufacturer implemented 5-axis technology its error rate in production fell from 8% to below 1%, driving a substantial reduction in labor related to defect management.
Unattended Operation Support
One of the most important benefits to more automation through 5 axis CNC machining is the ability to conduct operations unattended, ideally to some degree during off times. This leads to the potential of production being able to continue outside of typical working hours with no additional labor charge. A Vehicle Parts Manufacturer showcased their feat of being able to perform a 20-hour production cycle with new 5-axis machines instead of two 8-hour shifts with all available manpower.
Improve Precision and Accuracy
With 5-axis CNC machining, the precision and accuracy in the final finishing of the products will improve, hence reducing the cost of labor. Since you put out better parts more consistently, the need of post-processing quality control and corrective labor is dramatically less.
Reduced Quality Control Labor
5-Axis CNC machines can produce intricate geometries with a minimal tolerance for error, which leads to less variability in the finished parts due to defects in production. This accuracy will directly reduce the labor of inspection personnel. In one case, with 5-axis manufacturing of aerospace components, the reduction of quality control staff hours attributed to the improved accuracy went from 60% less time. This results in fewer parts in need of inspection, less rework required.
Reduction rework and scrap rates
Higher accuracy and no errors does help a lot especially when you try to avoid rework or scrap which are expensive in materials and labor. This has led more engineering shops to transition to 5-axis machining, one of the largest engineering firms in the UK even reported a drop in scrap from 5% to less than 1%, saving you a lot on reducing the amount of waste material of your products, as well as saving in labour costs associated with binning old product. This enhancement was a savings of at least $50,000 per year in labor and materials, according to the company.
Efficient Material Usage
5-axis CNC machining provides high-performance potential around material removal, meaning less wasted material, more material usage per part, etc. In addition to cost savings through material reduction, this efficiency reduces labor costs associated with disposal/waste management. A car manufacturer reported a 20 percent improvement in material-utilization efficiency with 5-axis machines, or, in other words, so many fewer labor hours required to handle or process waste.
Efficient Post-Processing Steps
5-axis CNC machining allows for some of the best surface finishes in the industry, making it unnecessary for many parts to see as much post processing (i.e., manual polishing or finshing). This decrease in post processing not only increases turnaround times but also reduces the manual labor typical for these operations. For its part, a medical device company cut post-processing labor by 30 percent on one particular line after adopting 5-axis machining.
Complete Jobs Faster
With 5-axis CNC machining, you can do the job in just a few portions of the time a traditional 3-axis machine needed to do the job. The higher the speed, the lower the labor hours and cost to produce the same amount of parts.
Reduced Setup Rapid Machining
With 5-axis CNC machining, you will no longer need to separate jobs with it because it works on multi-sided of a part in other process has done previously. Some examples would be a complex part that may take three setups on a 3-axis machine, and can be done in one setup on a 5-axis machine. This consolidation of the two steps also saves time on the machining process, and save a significant amount of setup time. For example, an automotive parts manufacturer shared that adopting of 5-axis machining has had significant impact to the business including up to 70% reduction in setup times which means the projects could be turned around quicker and number of man hours reducing per part.
Increased Cutting Speeds
Due to their comprehensive positioning capabilities (except the head), 5-axis machines can also use shorter and more rigid cutting tools, since the tool can be positioned in the area of optimal proximity to the workpiece. This in turn results in increased cutting speeds and faster material removal rates, and a part made of exotic materials can be machined on a machine with HSK technology in less time. For example, a case study in industrial equipment manufacturing discovered that 5-axis technology increased their cutting speeds by 40%, an improvement that translated directly into reduced total machining time and, in turn, labor costs.
Enhanced Machine Dynamics
5 Axis machines have can use complex kinematics and geometry for faster, more accurate control of the tool path that improve machining efficiency. This motion is made possible by the machine tool with a very dynamic movement that allows for drastically reducing the time not in cut as it has the ability to perform therefore a very fast transition between cuts. A supplier of aerospace components was able to reduce their average machining cycle times by 50% compared to older 3-axis machines, resulting in a significant decrease in the labour cost per unit through the adoption of 5-axis machining technology.
Optimized Tool Paths
5-axis CNC machining provides custom parts with heightened precision and a more accurate tool paths, shortening the area where the tool moves during a workpiece is forming. Advances in this area not only improve cutting speed but also prolong tool life and protect the machine from wear, leading to reduction of downtime and maintenance costs. The strategic use of 5-axis machines in combination with an optimized tool paths can decrease total machining time up to 30%, a report published by a machine tool analytics firm.
Reduce Setup Time
That is a huge saving in labor cost and one of the primary reasons 5-axis CNC machining is so beneficial in this regard. This feature is especially important in high-mix, low-volume manufacturing with many recipe changes.
for Multiple Face Machining
5 Axis CNC machines are able to machine complex parts in a single set up having multiple faces of the part accessible at the same time. It would replace the many setups typically needed to machine complex 3D surfaces and with them the multiple opportunities for setups issues and errors. One aerospace parts specialist for example reported that 5-axis machining technology had reduced their average setup times on parts that were taking multiple hours, to less an hour per part decreasing labor requirements and accelerating overall production timelines.
Enhanced Tool Accessibility
Thanks to the increased geometrical range that 5-axis machines offer, tools can move to areas that are either hard to reach or require no specific fixtures or changes between setups. This means that machining is not only easier but the setup time per job is also decreased. 5-axis CNC machine to achieves a 50% setup reduction when machining complex surgical tools for a medical device manufacturer.
Automated Setup Features
Add to this the automated setup features of 5-axis CNC machines, like tool alignment and calibration, and set-up, in which much of the turn indicates a manual width to the set-up list, can be further minimized. These capabilities translate in faster – and better – execution of new retail signings with less mistakes and rework. A maker of 5-axis machine components for the automotive industry has seen setup time slashed by a further 30% with automation features on its machines, for better maximization of production rather than setting.
Reduction in Setup Labor
Shortened setup times, consequently, cut down on labor hours for machine setup overall. By reducing the setup labor, not only is direct labor cost reduced, but machine utilization rates improve as well. An industrial study confirmed that 5-axis CNC technology provides a 40% reduction in setup labor for companies, allowing them to complete a higher number of projects without additional labor costs.
