From First Impressions to Cycle Time...
-
Among the many processes involved in toolmaking, there is one essential step that is rarely discussed. Its cost and the time it requires are clearly visible, yet its real value is usually reflected only indirectly through indicators such as:
• cycle time,
• costs over the entire service life of the tool,
• part release,
• productivity and downtime,
• long-term reliability,
• maintenance requirements,
• product quality,
• manufacturing time and costs,
• customer satisfaction as a result of all these factors,
• and ultimately the marketability and competitive advantage of the finished product.Why is this the case, and how can we turn a process that is often treated as little more than a necessary evil into a genuine business advantage?
Perhaps the reason is that, during tool manufacturing, only the cost and time required for this process appear directly in reports, while its real impact does not.
- However, as the above list clearly shows, this is in fact a relatively small long-term investment with considerable indirect profit potential.
This process is surface finishing, and the result of a well-finished surface is far more than just an attractive appearance!
Modern machining centres provide an excellent foundation, significantly reducing the amount of manual work required, including surface preparation (see my next article: Cheap Polishing?). However, in many applications they cannot replace manual finishing, or it would simply not be practical to look for a fully machined solution.
If cycle time, part release, maintenance requirements, downtime and product quality are all considered important performance indicators, why is surface finishing and polishing so often regarded merely as a cost rather than as one of the factors influencing them—one of the potential tools for achieving success—when that is exactly what it is?
- Creating the required surface finish by hand is typically a one-time investment, whereas the consequences of an inadequate surface finish may recur throughout the entire production life of the tool.
Inadequate Surface Finish
- ✖ parts sticking in the mould
- ✖ manual intervention
- ✖ longer cycle times
- ✖ increased deposits
- ✖ higher release agent consumption
- ✖ ongoing costs and losses
- ✖ constant frustration and extra work
- ✖ delayed deliveries
- ✖ reduced product marketability
- ✖ customer complaints
Proper Surface Finish
- ✔ easy part release
- ✔ stable automated production
- ✔ shorter cycle times
- ✔ reduced maintenance requirements
- ✔ less downtime and lower material consumption
- ✔ one-time investment
- ✔ continuous production
- ✔ predictable production schedule
- ✔ higher perceived quality and a better first impression
- ✔ more satisfied customers
- Yes, surface finishing also has an influence on all of these factors, alongside other important parameters such as geometry, dimensional accuracy, cooling and many others!
In reality, everyone measures the results of surface finishing, yet the process itself is not always recognised as a factor that influences overall performance.
- By giving proper attention to surface finishing, you can achieve:
- 1. Manufacturing Benefits
• improved part release
• shorter cycle times
• reduced downtime
• lower maintenance requirements - 2. Economic Benefits
• lower long-term operating costs
• reduced losses
• less scrap
• more stable production - 3. Market Benefits
• a better first impression
• higher perceived quality
• greater customer confidence
• fewer customer complaints
- If you had to choose between these three sample products;
-
- which one would make the best first impression on you?
The right surface finish influences not only manufacturing efficiency, but also what the customer thinks about the product in their hands and the company that produced it.
- Interestingly, when discussing toolmaking, virtually every major process is mentioned—from design to CNC machining—yet surface finishing
is often omitted, even though its results are measured every single day.
For this reason, the effects of surface finishing should not be overlooked from either a technical or a business perspective, whether the application requires high-gloss polished, textured, brushed or functional technical surfaces.
Since cycle time, part release, downtime, maintenance requirements and product quality are all important performance indicators, surface finishing should be regarded not merely as an aesthetic process, but also as one of the factors influencing these results. Its importance—and the professional expertise behind it—should also be communicated to customers and business partners.
Whether carried out in-house or with the support of an experienced specialist, proper surface finishing is not merely a cost, but a long-term investment in manufacturing efficiency, the manufacturer's reputation and customer satisfaction alike.