Capacity, efficiency and flexibility are no longer optional in today's metalworking manufacturing climate-they are essential for survival. An area commonly scrutinized for cost reduction is found in perhaps the simplest of machining technologies: EDM wire. The consumption of EDM wire can often be a sneaky expense, but it is one ripe for savings.
Enter the FANUC ROBOCUT and FANUC control technologies.
While some EDM machines claim wire savings of 25% or more through coated wires and specialized feeding processes, these claims often apply only under specific conditions, such as certain part thicknesses.
FANUC took a different approach. By listening to customers and introducing its Wire Saving Function for all technologies, FANUC ROBOCUT delivers consistent savings without restrictions. This feature can translate to annual savings of $3,000 to $9,000 per machine, where wire consumption is about 60% of the consumables cost. This process delivers for a standard 40-hour-per-week shop through the 24-hour high-volume operation, all without compromising part quality or finish.
Simple adjustments are the key to operator efficiency as savings accumulate quickly across multiple machines. The results make consumable efficiency a critical factor in long-term profitability.
Energy efficiency adds another dimension to cost control. FANUC ROBOCUT machines feature intelligent power management systems that automatically shut down pumps and machine components when idle.
For a mid-sized shop operating 10 machines, this can mean annual savings of up to $1,000 per machine. Lower energy consumption not only reduces operating expenses, but it also supports sustainability initiatives with an eye toward environmental standards that appeal to eco-conscious clients.
Remote monitoring capabilities further enhance operational performance. By enabling real-time tracking of machine status, predictive maintenance, and troubleshooting from virtually anywhere, remote monitoring reduces unplanned downtime by up to 25%. Considering downtime costs can average $150 per hour in lost production, even modest improvements in uptime translate into significant financial benefits. This connectivity also allows managers to optimize scheduling and resource allocation, ensuring that every minute of machine operation is productive. ROBOCUT LINK-i is provided with all machines at no additional charge.
ROI snapshot:
- Wire savings: $3,000/year
- Energy savings: $1,000/year
- Downtime reduction: $5,000/year [Estimate]
- Total annual savings: $9,000/year
Let us say the machine costs $150,000. Therefore, the payback period is less than six years, before factoring in productivity gains from its generous 800 mm X-axis, 600 mm Y-axis, and 500 mm Z-axis. This expanded work envelope allows manufacturers to handle larger, more complex projects with fewer set-ups or keep multiple set-ups ready to go, reducing set-up times and increasing throughput. The ability to consolidate operations on a single platform also minimizes labor costs and improves workflow efficiency.
The combination of consumable cost savings, energy efficiency, remote monitoring, and a larger work envelope represents a holistic approach to modern machining. It is not just about cutting metal; it is about cutting costs, reducing waste, and minimizing downtime and the life of a machine. For manufacturers seeking to remain competitive in a rapidly evolving market, investing in such technology is not a luxury-it is a strategic necessity that delivers measurable financial and operational benefits for the long haul.
Authored by William Burba, FANUC ROBOCUT Product Manager, Methods Machine Tools
For more information contact:
Methods Machine Tools, Inc.
65 Union Avenue
Sudbury, MA 01776
877-MMT-4CNC (877-668-4262)
www.methodsmachine.com