Seven elements of zero scrap in EDM for non-standard precision round parts

 Since 15 years engaged in mold parts processing, Yize, a non-standard precision round parts manufacturer, has been aiming at "zero" scrap. As early as more than ten years ago, Japanese companies have realized "zero" scrap of EDM. In the past, because various facilities could not be compared with Japanese enterprises, now Yize mould equipment and surrounding supporting facilities are no inferior to those of that year. At this time, we should carefully analyze why Japanese companies can achieve "zero" scrapping. Now that there is no gap between our machines and their supporting equipment, what is the real reason why we can't achieve "zero" scrapping? For this reason, taking the non-standard precision round parts processing as an example, we summarized the following elements:

The first element of zero scrap: detailed process arrangement
Parts processing seems to be just the work of technicians on the processing site. However, due to the fact that the processing is divided into different procedures, whether our process discussion and scheduling are as detailed as possible, whether we have considered all aspects and whether there is any need to remind us that we need to pay attention to when arranging the production process.

The second element of zero scrap:the purpose of the design is to carry out EDM smoothly

When designing the electrode, we should discuss the rationality of the electrode design with the on-site processing personnel. We should go to the site every day to ask the field processing personnel whether the electrode is easy to use and whether there is a better design method. Only through this way of continuous communication and learning, can we make better connection between process and design, and improve our design level more and more.

The third element of zero scrap: perfect electrode quality
EDM to have good quality, must have high quality electrode processing guarantee! Our CNC electrode processing personnel should not only have the ability to process the electrode according to the CNC programming diagram, but also have the ability to ensure the quality of the processed electrode.

Fourth point to achieve "zero" scrapping:Three dimensional electrode measurement
The third dimension can accurately measure the omni-directional data of the electrode, and the quality assurance of the electrode is a crucial link in the "zero" scrapping plan. All tolerances of electrodes for 3-dimensional measurement must be ± 0.01. If there is out of tolerance and can not be specially collected, all returned to the electrode processing department for reprocessing.

Achieving zero scrap factor 5: all based on data
All on-site processing is based on data. Put an end to the traditional computer-aided counting of the electrode separation. On the machine, the center of the electrode is shifted to the center of the workpiece, and two allowance are left according to the data of the electrode diagram, and the first workpiece is processed immediately. Don't have the idea of spare parts, the first piece must be successful!

To achieve "zero" scrap elements 6: step by step to do every step
No matter how comprehensive the plan is, there will be a lot of human factors, such as the wrong number of programming input, offset and wrong direction, burr not made well, the workpiece is not placed properly, the direction is wrong, the workpiece is missing angle and so on. It's possible that there will be endless layers, if not, as long as we settle down, develop good habits, do every step step step by step, carefully check, reconfirm, and carefully do what we should do.

To achieve "zero" scrap factor 7: create a harmonious and stable working environment together
It is very important for us to create a harmonious working environment, so that everyone can keep a happy mood and work without being anxious or irritable. We should respect each other, help each other, encourage and create a harmonious working atmosphere together.

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