Value Engineering (VE)
Tooling Project
Summary:
While I Gentex, I led a team to change part designs to accommodate high-speed (HS) machining of plastic injected part molds.  Prior to this change, each tool would include dozens of electrical discharge machining (EDM) electrodes. On average, this saved about $8K to $10K per tool depending on the complexity of the design.  Gentex typically releases 20-30 such tools per year, for a cost savings in excess of $250,000 per year.

Not only does HS machining save on electrodes, but it also saves on other areas of the tool build.   Less time �spotting� the tool:  making sure all the shutoffs fit tight so there is no flash.  Our molders say this saves them about 6 to 8 hours per tool.  

Also less polishing is needed because the high-speed (HS) mill leaves a better steel finish than the EDM.
VE Benefits:
Reduction in the amount of electrode material.
Reduction in the amount of time spent cutting electrodes.
Reduction in the amount of EDM burning.
Reduction in the amount of polishing.
Reduction in the amount of spotting.
Typical tool build electrode assortment
Typical electrode assortment for a tool, before VE project
Tool build electrodes after cost-save
Electrodes and molds of typical tool after VE project
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