Engineering Industry
CNC Setup & Spindle Optimisation
Primary Outcome22% Spindle Utilization Uplift
Business Challenge
Custom machining shop lost 35% of CNC machine capacity to batch setup delays, fixture zero-setting, and CMM inspection waits.
Client Situation & Operational Bottlenecks:
- •Machinists spending up to 3 hours per batch locating tooling and fixtures
- •Manual trial-and-error part alignment on 24 CNC machining centers
- •Frequent delays waiting for CMM quality approval on first-off parts
- •Low spindle utilization (54%) resulting in missed customer dispatch dates
Our Approach
- Conducted setup time analysis across high-precision CNC machining centers
- Introduced zero-point modular quick-clamping fixtures for instant part location
- Established offline tool presetting routines to prepare tooling before machine stops
- Standardized tooling carousels and visual setup instruction sheets
- Implemented quick first-off part inspection protocols with dedicated gauge kits
Key Improvement Initiatives
- 1Equipped 24 CNC machines with standardized zero-point baseplates
- 2Set up a centralized tool presetting room for offline tool measurement
- 3Created visual setup binder checklists for all high-frequency part numbers
- 4Trained machinists on standardized SMED setup procedures
Before vs. After Operational Metrics
| Metric | Before Transformation | After Transformation | Quantified Impact |
|---|---|---|---|
| Average CNC Setup Time | 180 min | 111 min | -38% |
| Spindle Utilization Rate | 54% | 76% | +22% |
| On-Time Dispatch Adherence | 78% | 96% | +18% |
“
By shifting tool presetting offline and introducing zero-point fixtures, our spindle utilization rose from 54% to 76%. We delivered orders faster than ever.
— Director of Manufacturing, Precision Engineering Plant
KEY RESULTS
22%Spindle Utilization Uplift
38%CNC Setup Time Cut
96%On-Time Dispatch Rate
Services Delivered
- OEE & Spindle Optimisation
- SMED Setup Reduction
- Industrial Engineering
- Standardized Work
- Tooling Systems
Methodologies Used
SMEDIndustrial EngineeringVisual Management5SStandardized Work
Service Capability
OEE Improvement
Maximize equipment availability, performance rate, and quality output on critical assets.
Ready to Achieve Similar Improvements?
Speak with our manufacturing consultants to discuss similar operational improvement opportunities for your plant.
Request a Manufacturing Assessment