While it’s understandable that consumable cost is often a target for cost reduction, in a world clamouring for best practice, do the results justify the effort?
With modern grinding machines costing anything up to a million pounds, productivity or Overall Effective Equipment (OEE) performance of machinery and manpower can deliver multiple times the total consumable cost.
Assuming the cost for a machine, labour and overhead is £150 an hour, how does this compare to the consumable cost per hour? In recent tests using the latest generation of Viper wheels, Tyrolit was able to decrease cycle times by as much as 30%.
Considering a consumable unit costs approximately £25 each (for a Viper wheel) and the machine platform costs a £150 per hour, a 30% time saving reduction equals £45 – outweighing the cost of the consumable in one hour.
For companies looking to improve their grinding performance ToolScope – Tyrolit’s modular assistance software/hardware system – is a highly effective retrofit digitalisation of grinding technology.
The system creates measurable added value for customers through increased process transparency featuring numerous process options such as: OEE, collision detection, condition monitoring and more. This provides a window into machining practice and process. Each machine can be set up with minimum effort, within a very short time, subsequently allowing customers to save costs and time, as well as ensuring constant process quality reducing scrap, downtime and ultimately cost.
And as for the development of the Viper grinding wheel itself this has also been transformed down the years.
Pete Dufty, sales director at Tyrolit UK, says: “As we celebrate 25 years of partnership in the development of the Viper grinding wheel, the development and introduction of a third generation of grinding wheels is a complete gamechanger.
“The original orange Viper wheel, lovingly referred to as ‘The House Brick’ was superseded in 2007 by the Viper Ultra. By utilising Tyrolit’s bond technology with a super tough but cool cutting abrasive, a new revision of the Viper Ultra was produced, clearly identified by its blue colouring. This is a flexible product which adapts well to most aerospace applications and can be found in most of the world’s machining facilities.
“Tyrolit UK’s latest offering, a Viper Ultra Ceramic Hybrid wheel, uses our own manufactured ceramic blend but retains Tyrolit’s bond technology from its predecessors. Having only been on the market for 18 months, the results, its performance and the feedback from customers has been outstanding.”
An added benefit of Tyrolit’s Ultra Ceramic Hybrid wheel is its environmental impact. It is manufactured at lower kiln temperatures than previous products, contains no naphthalene, and with less dressing and more parts per wheel, reduces landfill, transport (COâ) as well as reducing demand for virgin material, safeguarding supply.
Mr Dufty concludes: “Grinding machine tools are precious to their manufacturers so they should protect their investment with ToolScope and invest in the latest consumable technology.”