A cutting tools SME using Electrical Discharge Machining (EDM) faced rising defects and scrap, causing 15% cost overruns on recent orders. The issue stemmed from unvalidated internal process rules, leading to inefficiencies. AEM Consulting was engaged to optimize their EDM process and restore profitability.
The client's primary challenge was the escalating scrap and defect rates across multiple EDM machines. This directly led to increased production costs, longer machining times, and unreliable output quality.
Key issues includes:
Continuing with these flawed parameters would have led to further financial losses, unreliable product quality, and diminishing competitiveness.
AEM began performing a detailed diagnostic to scientifically validate the machining issues.
AEM performed statistical hypothesis testing to confirm that:
This confirmed that the process itself is not human error, was the source of quality issues.
AEM conducted a structured Design of Experiments (DOE) using Taguchi Orthogonal L9 Array, varying key EDM parameters such as: Pulse ON time, Pulse OFF time, Current, Voltage, and Wire feed/discharge rate
This enabled precise, controlled experimentation to measure the effect of each factor on: Material Removal Rate (MRR), Surface finish, Dimensional accuracy, Defects occurrence
DOE revealed the exact parameter combination that minimized variation and maximized machining performance.
AEM used Statistical Process Control (SPC) charts to:
The post-intervention control charts showed significantly tighter process control and near-zero defect trends.
Multiple validation cycles were run using the optimized parameters to ensure:
This step ensured the new process settings were robust in real operations, not just experimental conditions.
AEM deployed a structured, scientific approach to fully optimize the EDM process.
Incorrect, unvalidated EDM parameters were confirmed as the primary driver behind scrap, poor accuracy, and long cycle times.
AEM designed and executed a complete DOE framework using the Orthogonal L9 Array, enabling systematic variation and precise measurement of EDM performance.
This allowed the team to determine: Main effects of each parameter, Interaction effects, and Optimal balance between removal rate and quality
A precise, validated parameter combination was established for every EDM machine, ensuring: Consistent machining, Maximum removal rates, Minimum surface defects, and Accurate dimensional control.
AEM rolled out the optimized settings across all machines and implemented:
This ensured sustainable adoption and repeatability.
We delivered a complete scientific overhaul of the client's EDM process using hypothesis testing, DOE with Orthogonal L9 Array, and SPC-based control systems.
By identifying the optimal machining parameters and enforcing process standardization, the client achieved:
This intervention not only restored profitability but created a sustainable process excellence foundation, giving the SME a competitive edge in the precision machining industry.
For expert assistance in process optimization, defect reduction, and enhancing manufacturing efficiency in complex industrial operations, please contact AEM Consultancy.