In casting operations, part separation and gate removal are two operations with high consumable costs. Because of these high consumable costs, a large focus is placed on getting the least expensive consumable that accomplishes the task. Without taking a look at the entire manufacturing process, such a focus can have negative effects on operations, like decrease productivity and increased total cost.
I would like to present the Systems Approach which is a strategic problem solving methodology shifting the focus of manufacturing improvements from task to system oriented solutions. Norton Saint-Gobain has embraced this philosophy, and is revolutionizing the way abrasive and machining operations are being evaluated.
The Systems Approach will introduce concepts like specific energy and threshold power in discussing the importance of understanding how an abrasive product is used. This quantitative understanding of abrasive and machining operations can provide quantum improvements in safety, quality, productivity and total cost reduction.