The Stability in the selection of process methods shall match the production quantity. The process methods will face different choices due to changes in the production quantity. The process sequence will be different when the product is in the trial production stage and the small batch production stage. In the trial production stage, the focus is on product overall structure verification and processing timeliness, and it is not sensitive to process costs. In the small-batch production stage, the focus is on process route verification, partial optimization of the single-piece structure and appropriate mold preparation. In mass production, the selected process will take cost as the top priority, optimize the process as much as possible and save costs. Below is a sample of a small corner piece:
Processing method I: calculating and using the shearing machine to cut the raw material → using folding machine to bend the material → marking, drilling and tapping;
Processing method Ⅱ: calculating and using the shearing machine to cut the raw material (several items can be combined) → using the punching machine to punch the bottom holes → using the shearing machine to cut the material into single products → using folding machine to bend the material → tapping;
Processing method III: making mold to process
Through the comparison of the above three process methods, it is found that all of these three methods can effectively meet the requirements of customers, and each method has its own unique characteristics. Process methods I requires a lot of labor and time (marking and punching), resulting in a large percentage of process waste. Generally, it is only suitable for the processing of single product. This solution is not recommended for mass production. Process method II requires many machine tools. The time is slightly faster, and multiple products can be produced at one time, which is suitable for small and medium batch production. But the material pieces needs to be cut after punching, which may cause a small amount of displacement of the holes. Process methods Ⅲ is to make the molds for all the necessary parts. This processing method is suitable for mass production, saving time and effort.
Through the above discussion, it can be seen that the influence from the selection of process methods to the waste in the production procedure is closely related to the production quantity. I think that the selection of the process methods should take various factors into consideration. Therefore, it is particularly important to appropriately select the process methods according to different production conditions.
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