Rethinking modular jigs’ design regarding the optimization of machining times

Abstract Machining of complex parts needs to be properly thought in order to save time and cost of making those parts. Jigs and fixtures are often overlooked as an auxiliary tool, but they can help in optimizing a machining process as a part of continuous improvement. The approach to this work was based on the increasing demand of the part named Winding cone 1 for 2019. This implies a reduction in the takt time from 4.6 to 2.6 minutes per part. Thus, this paper aims to find an optimal jig solution for winding cone 1, which was divided into four phases, namely: research, design, machining and implementation. The research phase included the study of the old jig, as well as other solutions already developed by other authors. The design phase was based on the Design for Six Sigma (DFSS) methodology for the fixture. Various iterations of the jig components were designed, assembled and tested using Solidworks CAD model. The critical outcomes of the project were harvested from the implementation phase. The modular jig was able to machine 12 parts per cycle, proving to increase the number of parts machined per day by 32%, with expected savings of more than €6000 per year in machining cost. The added benefit of a modular jig system was that one base (skeleton of the jig) could be used in machining different products.