machine investment, service costs represent just over
4%, about double the amount suggested by the VDMA
(the German Association for Machine and Plant
Manufacturers). The reasons for the disparity may be a
combination of harsh operating conditions, frequent
personnel changes and poorly trained operators.
Personnel costs, in spite of higher automation,
should not be underestimated as a cost factor. This
example is based on multiple machine operation.
Assuming that 20% of the personnel costs are for
setting-up, cut piece removal from and order entries
relating to any given saw, the costs amount to an annual
total of 26,400 Euro per saw, based on 220 working days
and three-shift operation.
Figure 2 shows that over the first 10 years of a
KASTOtec AC4 bandsaw’s life, machine investment
represents only 15% of the total costs, compared with a
massive 48% for tooling costs and 32% for labour. Other
cost elements are coolant (1%) and service (4%). In
respect of the latter, speed and quality of service are
important, as if spares are missing or not fitted correctly,
the result is machine downtime and lost production.
Figure 2
Total costs: KASTOtec AC4 compared with
conventional machine
Comparing all lifetime costs of the KASTOtec AC4
with those of a conventional bandsaw, Figure 3 shows
that a traditional machine requires around 50% less
investment and 43% less in high-speed steel bandsaw
blades due to the machine’s shorter operating life. So
taking into account just these two factors, the machine
is around 30% cheaper.
You can now programme where you want to go - and let the machine work out the best route to take
‘Satnav’ for bandsaws
WHILE bandsaw machines and bandsaw blade technology have made huge advances over recent years, the one major factor that can influence efficient
cutting is the operator’s accumulated experience. This tends to determine the speed the blade runs at and the downfeed rate of the machine; so it is the saw
operator - not management - that controls production and consequently dictates overheads in terms of blade life and costs.
Danobat has recognised this weakness and has introduced the PASO PASO control system to address it. This new system allows companies to achieve
maximum production rates together with optimum blade life, with minimum input from the operator. By simply selecting the material grade from a chart on
the machine - carbon steel, stainless steel, nimonic or non-ferrous materials, solid or tube etc - the machine will automatically set its own parameters in terms of
cutting rates and blade speed and will continually adjust itself, depending on the cross section of material and the blade condition.
While most material specifications are pre-programmed into the machine, there are spare programs so that companies can add their own specific material
groups, if required. Another innovation is automatic ‘running-in’ of a new blade, both bi-metal and carbide. This tends to be neglected and can result in
premature blade failure. The Danobat system not only eliminates the guess work, it allows the operator to input a specific make of blade to ensure that the
correct running-in procedure is being followed. The machine will also calculate the weight of each cut component and display that weight on the control
console. The result is maximum production and optimum blade life.
www.prosaw.co.uk
may 2008
Figure 3
Figure 4 & 5
sawing & tubeforming
Nevertheless, investment in a more expensive, high
performance machine is justified from both
technological and economic standpoints. First, a
carbide bandsaw can cut tough materials up to a tensile
strength of Rm=2000 N/mm 2, which cannot be sawn
with traditional machines or blades. Second, the carbide
saw has a more efficient cutting performance, resulting
in shorter cycle times. Third, longer band life requires
less frequent band changes and therefore reduces
labour costs and machine downtime.
A productivity comparison shows that over a period
of 10 years, the carbide machine cuts 2.6 times more
material than a traditional machine (Figure 4). If one
converts the total cut surface to cost per square metre, it
shows that the figure for the KASTOtec AC4 (Figure 5)
is 48% lower than for the conventional machine.
www.kasto.uk.com
MWP
73
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