James Womack and Daniel Jones, in their 1996 book Lean Thinking, defined Lean as “…a way to do more and more with less and less—less human effort, less equipment, less time, and less space—while coming closer and closer to providing customers exactly what they want.”
Implementing Lean manufacturing helps address these types of waste: defects, over-production, waiting, non-utilized talent, transportation, inventory, motion and extra-processing.
How can Lean manufacturing help a company?
Manufacturers in metal fabrication industries can use Lean principles to eliminate waste, reduce expenses, optimize processes and improve quality with innovative solutions to keep pace in a constantly evolving global marketplace.
For companies that need to manufacture precisely machined parts with a high-quality consistent finish for industries such as aerospace, energy, powertrain, medical, and firearms, using the innovative and automated deburring and finishing process that Xebec Deburring Technologies provides is a way to achieve Lean principles – to do more with less, improve productivity and provide customers the results they want.
Challenges in implementing Lean manufacturing
Qualified labor shortage: There’s a qualified labor shortage in the manufacturing and machining industry. Although US manufacturing activity soared to a 37-year high in March, there are more than half a million jobs open. Skilled workers for specialized roles such as welders and machinists are difficult to find. Additionally, turnover can be high and, when turnover occurs, there’s a new learning curve for remaining employees to take on along with their regular job duties.
How Xebec can help: With Xebec ceramic fiber brushes and cutting tools for deburring, the task of hand deburring can be eliminated and operators can be upskilled or reallocated to other tasks such as transportation, quality control or manual machine operator.
Reallocating resources: By trying to implement LEAN, you’re not trying to eliminate people, you’re trying to better allocate people. Xebec deburring solutions allow the available resources on-hand to ramp up production while producing higher quality parts.
How Xebec can help: Xebec is a cost-effective solution that pays dividends in the long run through increased productivity, improved quality and reduced costs. See how Xebec can pay off for your organization.
Time to implement newer, better processes: Engineers and programmers have difficulty finding time to research and implement new technologies. It may be easier to leave a hand-deburring process in place than implement a new technology because it’s a known quantity, but that’s a short-term solution that is more expensive in the long run.
How Xebec can help: Xebec helps engineers initiate new deburring solutions for their parts. An engineer can give Xebec’s knowledgeable reps a part or 3D file and tell them what they need done on it. Then Xebec will help design a process to achieve their desired result and coordinate test runs to facilitate the finished product. Have technical questions? Call our technical hotline at 800-434-9775 to get started today.
Commitment to doing the work upfront for long term gain: With production ramped up for most companies still dealing with a labor shortage, setting aside staff’s time to implement new technologies and processes is difficult. However, there’s no better time to implement innovative technology that saves time and money than in these competitive times, especially for growing industries such as aerospace, energy and firearms.
How Xebec can help: Xebec provides programming and training support to their customers to ease the workload. Xebec helps with testing, design, installation and training of operators to ensure the best possible results. Meet our team of industry experts.
Negative mindset: Many company leaders and staff are hesitant to implement newer, better processes. It’s easier to stay in the status quo than implement new technology or software. Those hesitant to change may be close to retirement and don’t want to learn anything new and others may fear their jobs will be eliminated. Overcoming objections is difficult but necessary to remain competitive in today’s market, especially with growing industries that require precise edge breaks and flawless finishes.
How Xebec can help: To overcome objections, Xebec’s sales reps can arrange visits to similar companies to see how the Xebec product helps them meet Lean manufacturing principles or have them talk with a company that has ramped up production using Xebec. Read our Area Tool Case Study to see their results from implementing Xebec.
How to apply Lean manufacturing with Xebec deburring solutions
Manufacturers look to Xebec to free up capacity and get more parts off of a machine in a given time period. They’re also looking to get a more consistent, precise deburring process to meet tight tolerances and eliminate expensive scrap.
With Xebec deburring solutions, manufacturers can save time, reduce expenses, improve quality and increase production while preventing defects, over-production, non-utilized talent, waiting and excess transportation and processing.
Streamline Production and Processing
Automating processes eliminates over-production and help address the labor shortage. Pairing Xebec tools with robots or integrating them with the CNC machine process saves time and streamlines production. By deburring and finishing a part in one step, Xebec reduces extra-processing.
Reduce Waiting
Machinists can take 10 to 15 hours into a setup to do one side of a part, especially if it’s a large part like a rocket housing. When they flip that part to the other side, now they have an additional 10 to 15 hours in the setup time. So while the machine is set up for that part, the goal is to run multiple parts before they have to flip it, re-fixture and redo everything to do the other side of the part. Integrating the deburring and finishing process with the CNC machining will speed this process up immensely.
Prevent Non-Utilized Talent
By using Xebec deburring solutions, personnel can be upskilled and redeployed from hand deburring to CNC machine operation or other revenue-generating tasks. Automating the deburring process also reduces operator injuries and the cost of compensation claims.
Reduce Transportation
Some parts that need deburring and finishing are so large, moving them from one process to another is tremendously expensive and time consuming, especially if that process must be outsourced. Having a deburring solution that is integrated with your CNC or robot reduces the number of times a part must be moved or re-fixtured, reducing transportation and labor costs and preventing injuries.
Reduce Defects
Defects can be reduced when there is consistency and reliability in deburring and surface finishing. By eliminating hand deburring with Xebec solutions, companies can achieve edge break and tight tolerance requirements and reduce defects and scrap, saving money.
Achieve Lean principles with a 21st century deburring tool
Implementing Xebec’s innovative deburring and finishing solutions, organizations can achieve the principles of Lean manufacturing: Do more with less human effort, less equipment, less time and less space—while providing customers exactly what they want.
To learn more about Xebec’s products, check out our video or contact us to see how we can help your organization.
