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Overview
Overview
A cutting tools SME using Electrical Discharge Machining (EDM) faced rising defects and scrap, causing 15% cost overruns on recent orders. The issue stemmed from unvalidated internal process rules, leading to inefficiencies. AEM Consulting was engaged to optimize their EDM process and restore profitability.
The Challenge
The Challenge
The client’s scrap and defect rates had surged, directly causing financial losses. The root problem lay in the use of non-optimized internal EDM parameters, which led to inconsistent material removal rates, higher rework, and unmanageable waste. Without specialized knowledge, the client was unable to identify or implement the optimal EDM settings needed for efficiency and quality.
The Solution
The Solution
AEM Consulting adopted a scientific, experimental approach, working alongside the client’s engineers and operators to optimize EDM parameters:
Root Cause Analysis: Confirmed that the main issue was incorrect, unvalidated EDM parameters, leading to poor machining outcomes.
Experimental Optimization: Designed controlled experiments that systematically varied EDM parameters to assess impact on removal rate and quality.
Optimum Settings Identified: Established precise, validated parameters for each EDM machine to maximize removal rates while minimizing defects.
Standardization & Training: Implemented new parameters across machines, with comprehensive operator training to ensure consistent, high-quality machining.
Results
Results
The optimized EDM process delivered immediate and transformative outcomes:
90% reduction in defects and scrap, drastically cutting material waste.
95% reduction in rework and losses, eliminating the 15% cost overrun and restoring profitability.
Faster machining cycles with maximized material removal rates, increasing throughput.
Improved operational efficiency through uniform, defect-free machining.
Optimized energy use, as the new parameters also led to more efficient electricity consumption, lowering operating costs further.
This intervention demonstrated the power of data-driven process optimization for SMEs. By replacing trial-and-error with structured experimentation, the client not only recovered profit margins but also built a foundation for sustained efficiency and competitiveness in a high-precision industry.
For expert assistance in process optimization, defect reduction, and enhancing manufacturing efficiency in complex industrial operations, please contact AEM Consultancy.
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