Why don’t 10 machines always produce twice as many?

If 5 machines produce 5 products per minute, why wouldn’t 10 machines produce 10 products in the same time? The answer lies in the overall production process: material stocks, intermediate stocks, material flows and labour load can limit capacity growth. Simply adding more machines does not automatically mean more efficient production if other critical resources are not kept up.

The problem has also been that simulation software costs a lot of money and there is a shortage of simulation experts. In many cases, it has been cheaper to buy an extra machine than to do the necessary simulations. But not anymore.

A cost-effective solution for optimising production

Now we finally have a cost-effective solution for this market that allows production capacity to be accurately optimised – without the need for rigid simulation models and high costs. The simulation model can be easily built, even for an entire factory and thousands of different product variants.

At Hefmec, we have already helped many of our customers to use these simulations to assess the return on investment and optimise the number of production machines and the necessary intermediate stocks when increasing production capacity. These analyses help us to identify which investments really add value – and not just more machines waiting on the production line.

How do production simulations help decision-making?

1. Identifying bottlenecks – Simulations can be used to identify where production slows down and what factors are limiting capacity.
2. Optimising resources – Matching machinery, labour and material flows improves efficiency and reduces waste.
3. Cost management – By simulating different investment options, it is possible to predict which solutions will deliver the best return.
4. Real-time validation – Our simulations are not just based on theoretical models – we have validated them with real production data. This means that our models reflect real production conditions and we ensure that they are accurate enough to predict the impact of investments.

Learn more about our services and products, or contact us!

Written by Sami Jortikka, Senior Project Manager

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We helped the customer solve a structural strength problem, which resulted in a patented machine.

What is embossing?

“Chiseling is a method used in the processing of metal products, in which a chisel is used to finish the surface material being processed by cutting or pressing it into the desired shape. This method is sometimes also referred to as ‘stamping,’ although that term is more commonly used to describe a similar process in the printing industry.” (Wikipedia)

Why doesn’t the pin withstand the pipe being cut?

By the spring of 2020, I had been working at Hefmec for about two years while pursuing my master’s degree. I had already seen many different projects in the automotive industry, the food industry, the heavy machinery industry, and many other sectors. Then, during a client project, I encountered a situation that, at first glance, seemed quite harmless:

The customer was developing a punching machine intended to perform a lateral punch on a tube—a task known in advance to be challenging. This was a new method for which high expectations had been set. However, in practical tests, none of the tested punches withstood the demands of use, and as a result, the machine developed by the customer could not be completed.

Hefmec Takes on the Challenge

We had been providing mechanical design services to this highly innovative client for years. The division of labor was clear: the client has decades of experience in solving problems in their own field, and we have extensive experience in utilizing modern 3D design software. For this reason, we were a natural partner to tackle the challenge that had now arisen. Even in the early stages of the project, all parties had a well-informed hunch about the root cause. As we began to examine the challenge more closely, it became clear that, in addition to being a tricky problem, this might also provide material for a thesis.

Root Cause Analysis: The Challenge of Forces Acting on the Blade

Normally, in milling, the material is cut at a right angle, so the forces acting on the tool are parallel to the cutting edge, and their bending effect is minimal. The customer tested various blades without seeing any significant improvements in the cut quality or blade durability. When piercing the tube laterally, the challenge was the lateral forces acting on the tip of the blade, since the blade’s movement does not occur perpendicular to the surface of the tube. These lateral forces caused severe bending at the blade tip, resulting in the cutter failing after only a few penetration cycles.

Simulation of a Problem Situation and Search for the Optimal Geometry

The blade was designed to reduce the forces acting on it. The blade was modeled during the various stages of the cutting process, and the shape of the cutting edge was examined in relation to the resulting hole. The goal was to shape the blade edge so that chips would be removed by shearing rather than tearing.

Reaching a Solution Through Practical Experiments

1. Correct clearances
   Determining the correct clearances between the cutter and the workpiece was also taken into account. A smaller clearance produces a better cut, but on the other hand, a larger clearance reduces the forces acting on the blade. The correct clearance, which produced a satisfactory cut, was ultimately determined through practical testing.
2. Lubrication
   Lubrication was also added to the blade to reduce friction. This made it possible to further reduce the force required.
3. Material
   Powdered steel was selected as the material for the final blade, as it offered the ideal combination of toughness and hardness. This was further combined with a suitable surface treatment, which made the blade’s surface sufficiently wear-resistant.

The project resulted in a durable blade that also produced a clean cut. The client was able to file a patent for the machine, and I received high marks for my thesis!

Do you face similar challenges related to machining or other manufacturing processes? Please contact Product Manager Petja Lindström (+358 40 740 4771), and together we’ll develop the tools and methods that work best for you!

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As a remedy, Rahapodi prescribes productivity growth, the formula they have already repeated: more, better, with less.

As I listened to this, I was driving to meet a long-time client. While listening, I reflected on my own role in solving this problem. This sounds like the kind of problem whose solution would benefit all of Finland and would be a truly significant challenge to tackle. After a moment’s thought, a light bulb went off in my head—that’s exactly what we do at Hefmec! After all, our services are always aimed at increasing productivity. This is also supported by our slogan, “Productivity Engineering.”

How do we respond to the productivity challenge?

1. Project – In the implementation of investment projects, we help create opportunities to manufacture new products in Finland or expand existing production. In these projects, we often operate as part of the client’s organization, ensuring that projects are carried out according to plan. We often take on the management and execution of a project or part of it, which gives our clients the freedom to focus on their own core business. This not only speeds up project completion but also improves the quality of the end result.
2. Design – We develop work methods and tools that support increased productivity in manufacturing by enabling tasks to be completed faster, more safely, with higher quality, and/or using fewer resources. Design projects can be part of a larger whole or solutions to specific areas for improvement.
3. Products – We turn designs into delivered and commissioned products, at which point the designs are truly put into practice. Increasing productivity requires reliable production equipment and tools. That’s why all our products are designed and manufactured to last—for a long time.

All of the examples above aim to produce more and better results with fewer resources.

If your company aims to increase productivity, Hefmec is ready to help you overcome these challenges! Together, we can be part of the solution that leads you—and, by extension, the Finnish economy—toward a more stable and brighter future.

Learn more about our services and products, or contact us!

Written by Mika Julin, Project Manager, Account Manager – Pharmaceutical Industry

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For example, in the pharmaceutical industry, user requirements and requirement specifications are often defined with a high degree of precision. This is done to comply with Good Manufacturing Practice requirements and, thereby, to ensure patient safety. In some industrial sectors, a user requirement might be as simple as an email requesting, for example, a carrier.

If the user requirement is extremely stringent on all points, the technical implementation may require almost scientific breakthroughs. Similarly, overly detailed requirements can limit the options. From an engineer’s point of view, the best way to record a requirement is by referring to standards or regulatory requirements.

The impact of the user requirement, and its scope, depends on the scale of the investment. In smaller projects, even strict requirements can often be met, but in larger projects, one poorly written requirement can cause complex problems. This is why it is important to review and update user requirements during the project. However, problems can arise if a party has performed in accordance with the original requirements and then the requirements are changed. At this stage, disagreements may arise over funding and other implications of the change.

On the other hand, too light source data and user requirements can also cause problems. Typically, this takes the form of a very narrow definition, such as “a conveyor is needed” or “a robot is needed”. In such situations, the customer’s real need remains unclear, with the result that the original root cause cannot be corrected.

Because of these examples, we offer the customer the opportunity to take small steps forward. For example, with a few days of work, we provide the client with a concept-level summary of how we see their challenge and what we think would be the most cost-effective way to address it.

If you need tips on user requirements and general production development, please contact Kimi Forsberg (+358 50 563 0465) or Pertti Yli-Kohtamäki (+358 44 325 0076)! Whether it’s the development of a single work phase or the implementation of a new production plant or line, Hefmec can help you for an hour or a financial year, depending on your needs.

You can read more about our services here.

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