How can we control EDM operational costs?

 

In manufacturing, we’re always looking for ways to make processes more efficient and economically sound. The cost of running wire EDM machines is no exception. Wire EDM has been a revolutionary innovation in the tool and die, mold, and metalworking industries, and there are many reasons why you may choose to utilize it in your workflow. But whether you’re already using it, or considering investing in such machinery, you’re probably considering the expenses involved, and what can be done to control EDM operational costs.

 

In order to talk about cost-controlling measures, we’ll need to look at what the expense of running EDM machines really involves. Of course, there is the upfront cost of purchasing the system, and I’m sure you’ve already done your due diligence in that regard prior to making that procurement decision.

 

But what about the ongoing EDM operational costs? There are three main expenses to consider.

 

1. The machine itself. By this we are referring of course to the payments on the machine’s financing, but also to the tax rate and other related costs as well. As mentioned, by the time you have the machine in your factory, this expense has probably already been evaluated and set and not something you can change to reduce expenses.

2. Overhead. In other words, building costs, prorated for the amount of square footage devoted to the wire EDM machine. Again, these costs are relatively fixed.

3. Operational cost. This includes operator labor costs, electricity, and repairs, as well as materials, including resin, spare parts, and the wire used in the EDM process. It’s the last of these, the cost of the wire, which we can focus on in our attempts to control EDM operational costs.

 

Of the three main expenses, operational costs provides the greatest potential for cost savings. Wire is, in fact, the greatest expense involved in the EDM process. Tom Frick, of Intricate EDM, of Lancaster, PA, commented, “The price of a wire EDM machine is nothing compared to the cost of wire over the life of the machine.” While large efforts have been made towards increasing the speed and efficiency of the machining process, efficiency of wire consumption, or the lack thereof, has been largely neglected. Considering that the brass wire used in EDM can cost $5 or $6 per pound, and other, premium wires may run as much as $12 per pound, this may be a costly oversight.

 

While your cost and potential savings in this area is certainly dependent upon the type and volume of work you’re doing, significant reductions in total cost of ownership can be made here. Keep in mind that an improvement of 40% to 50% in efficiency of wire consumption will be seen as a reduction of $8000 to $10,000 in expense per year, for each machine, for each shift.

 

An interesting success story is that of the Vanderhorst Brothers, a mid-sized precision machine house in Simi Valley, CA. They were able to make significant improvements by replacing two older machines with one newer, faster burning machine that lowered their wire consumption and eliminated the overhead of running a second machine. Running this machine for about 2,000 hours (one shift) per year, they were able to realize a dramatic improvement to their bottom line.

 

There are, of course, other areas where costs can be reduced, including more energy efficient machines and lower resin consumption. But as the single greatest expenditure in the process, reducing wire consumption is the most effective way to control your EDM operational costs, and choosing the right machinery will enable you to do so.

Don't forget to take a look at some of the best rated companies while you're here. Lists are broken down by service to make it easy for you to find what you're looking for.