Reducing Costs with Modular Machining

Background Information

A customer approached Yumoto Electric with a request to manufacture a large component (over 1,000 mm in width) within a strict budget. The part required high dimensional accuracy and included several fixed mounting areas. According to the original design, the part was to be machined as a single solid piece with precise 90-degree corners to ensure a tight assembly fit.

Problem Statement

While the customer’s design met functional requirements, machining the entire component as a single piece would have been extremely costly. The size and complexity of the part meant that nearly all areas, except for the fixed mounting points, would need to be removed by cutting, resulting in long machining times, heavy material waste, and higher costs. The challenge was to achieve the required accuracy while keeping manufacturing expenses under control.

Solution Implementation

After reviewing the drawings and discussing the part’s intended function, Yumoto Electric engineers proposed modifying both the design and machining method.

Instead of machining perfectly square 90-degree corners, the team suggested drilling holes in the corners to achieve the necessary clearance. This simple adjustment reduced tool wear and machining time without affecting fit or performance.

More importantly, the team proposed adopting a split-part machining approach. Rather than producing the entire part from a single block, the large component was divided into smaller, manageable sections. The fixed mounting points were tapped and then fastened to the main body with screws. This modular configuration allowed for more efficient machining of each piece and minimized material waste.

Results

By applying the split-part machining method, Yumoto Electric successfully reduced total machining time, material consumption, and overall production costs while maintaining the same level of dimensional accuracy and functionality. The redesigned part met all performance requirements and was delivered within the customer’s budget and lead time.

This case demonstrates how rethinking design details and machining strategies, such as using modular or split-part approaches, can result in substantial cost savings for large-scale components without compromising quality or precision.