In modern industry, laser cutting technology offers a revolutionary solution for precision cutting tasks. However, producing scrap parts not only causes economic losses but also places a significant burden on the environment. In this blog post we look at how scrap can be minimised, and thereby how waste can be reduced during machining processes.
Table of contents
Analysing the scrap problem
Scrap parts are unavoidable in manufacturing processes, but reducing their share is key to sustainability and economic efficiency. To reduce scrap, we need to understand the causes of defects, which can be technological faults, material defects or human factors.
Methods for reducing scrap in laser cutting
- Precise settings:
- Calibration: Accurate setup of laser cutting machines is critical for defect-free operation. During calibration, it is checked that the laser beam is properly focused and that the cutting paths are accurate.
- Regular maintenance: Regular inspection and maintenance of the machines ensures that the cutting head and the optical systems are clean and working properly. Regular maintenance reduces the risk of mechanical failures.
- Optimising cutting parameters: Setting the cutting speed, laser power and focal point precisely helps to minimise faulty cuts.
- Software updates: Updating the software we use regularly ensures that we benefit from the latest improvements and fixes, which improve machine performance.
- Monitoring temperature and environmental conditions: Controlling the temperature and humidity of the production environment helps keep the machines running stably. In addition, when cutting materials of different thicknesses, continuous laser cutting also heats the workpiece, so to achieve a clean laser cut the power sometimes has to be reduced in proportion to the heating.
- Trained personnel:
- Basic training: Operators receive thorough training on how laser cutting machines work, including settings and maintenance procedures.
- Continuing education: Ongoing professional development and further training allow operators to stay up to date with new technologies and methods. Operators learn how to detect and correct errors during the production process.
- Standardising workflows: Introducing standardised procedures and protocols reduces the chances of error and increases work efficiency.
- Communication and cooperation: Teamwork and effective communication promote the rapid identification and resolution of problems.
- Motivation programmes: A strong company identity, together with motivating and recognising operators, raises morale and commitment, which improves production quality.
- Using quality materials:
- Inspecting raw materials: Thorough examination and quality control of materials ensures that only the best-quality raw materials are used. Identifying and eliminating material defects reduces the scrap rate.
- Reliable suppliers: Long-term cooperation with reliable suppliers ensures consistent quality and reduces the occurrence of material defects.
- Traceability: Tracking the procurement and usage chain of materials helps identify potential problems and respond to them quickly.
- Avoiding material mix-ups: Properly separating and handling material types reduces problems caused by parts being made from the wrong material.
- Optimising storage conditions: Proper storage of materials preserves their quality and reduces the risk of damage and surface defects.
- Continuous monitoring and improvement:
- Data collection: Analysing data collected during the production process helps identify the sources and trends of defects. Based on the data, settings can be refined and processes improved.
- Real-time monitoring: Using modern software and sensors enables real-time process monitoring and immediate intervention if an error occurs. This reduces the likelihood of producing defective products.
- Feedback system: Regularly collecting and analysing feedback from operators and maintenance staff helps identify and improve problem areas.
- Benchmarking: Comparing against and applying the best industry practices and standards improves process efficiency.
- Innovation and experimentation: Trying out and introducing new technologies and procedures helps to continuously improve production processes.
Environmental and economic benefits
Reducing scrap not only serves environmental goals but also delivers significant cost savings. Less waste is generated, which lowers waste-disposal costs and the need to purchase raw materials. In addition, more efficient production processes increase productivity and improve the competitiveness of the company. Improving energy efficiency and cutting waste contribute to more sustainable operations.
Case study: a successful implementation
A well-known manufacturer of hospital and industrial doors switched to laser cutting to produce the door cover plates. By moving to an automated technology, the company managed to cut the production time of the door panels by 50%, and thanks to CNC press-brake bending the joining edges were consistently produced to the same quality, so with our help they were able to reduce their previous 20% scrap rate to 2%. This saved them a great deal of time and money.
Summary
A laser cutting technology applied correctly, together with minimising scrap, brings significant environmental and economic benefits. Precise settings, trained personnel, quality materials and continuous improvement all contribute to making production processes more sustainable and efficient. For companies, minimising scrap is important not only for cutting costs and increasing competitiveness, but is also essential for reaching sustainability goals.
Sources
https://www.acra.com.au/3-tips-for-reducing-wastage-laser-cutting
https://www.cnclasershop.com/news/how-to-reduce-metal-waste-and-ensure-cutting-quality.html
https://www.trumpf.com/en_INT/newsroom/stories/seven-ways-to-cut-material-wastage-in-sheet-metal-processing/
