Maximizing Productivity in Hydropower Manufacturing: A case study on milling optimization and operational efficiency

This full-line supplier of hydropower plant equipment covers the entire life cycle and all components of large and small hydropower plants: from generators, turbines, pumps, electrical and mechanical power plant equipment and automation systems such as measuring, control and command systems, to services including spare parts deliveries and maintenance work.

Their focus on service, automation and modernization requires a strong commitment to continuous improvement to keep their operations running at the highest levels of productivity to meet customer demand.

Learn more about our MillMax® service at mscdirect.com/solutions/millmax.

IDENTIFIED OPPORTUNTIES TO INCREASE OPERATIONAL EFFICIENCY

• Need to identify optimal milling parameters for extended length tool

• Increase cycle times for higher productivity

• Increase tool life

MSC'S METALWORKING SPECIALISTS CONDUCTED MILLMAX® TAP TESTS

• Regional MSC Metalworking Specialist conducted a virtual MillMax® test

• Tested various combinations to decrease depth of cut to optimize application

• Delivered dashboard with optimized parameters for 22” long extended tool

ENHANCED OPERATIONAL PRODUCTIVITY

• 45% increase in speed

• 95% increase in feed

• 235% increase in tool life

“In optimizing the tool in this application, we were able to increase feeds, speeds and tool life while having to decrease depth of cut to stabilize cutter in accordance with the MillMax® dashboard. Although it decreased our (MMR) Metal Removal Rate, it provided less wear and tear on the spindle due to the enormous stress being put on it with the tool sticking out 22 inches. Based on the results to date, we will be working with this customer on other applications for 5 more MillMax® tap tests.”

Albert Lugo MSC Metalworking Specialist