DePuy Synthes

Depuy Synthes Achieves Process Predictability With Third Wave Systems

DePuy Synthes needed to improve the production process for one of their orthopedic implants. To improve process predictability and meet their bold production goals, Depuy Synthes identified machining modeling technology from Third Wave Systems. With the expected increase in demand for their products, the company had a goal of increasing the output of their existing CNC machines, while reducing the consumable costs. 

OPERATION 1 – How Depuy Synthes Improved Tool Life by 66% 

CHALLENGE 

  • Needed to improve tool life from 30 parts per drill
  • Focused on 9.1 mm drilling tool

APPROACH

  • Studied multiple drill point geometries with various conditions
  • Reduced RPM from 1346 to 802 to lower temperature
  • Replaced conventional drill with a split point drill to reduce axial force
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IMPACT

  • Temperature reduction resulted in improved tool life
  • Tool life increased from 30 parts per drill to 50 parts per drill

OPERATION 2 – New Toolpath Strategy Saved $586K In One Year

CHALLENGE

  • Needed to improve throughput by reducing cycle time
  • Focused on the boss/stem milling toolpaths

APPROACH

  • Created different toolpath strategies in the CAM system
  • Selected and optimized the spiral toolpath based on detailed analysis using Production Module
  • Machine trials were run to verify the savings on the production floor

IMPACT

  • Achieved average cycle time reduction of 24% 
  • Reached weighted average savings of 14.26 minutes per part
  • Improved surface finish from Ra of 66 µ to 56 µ
  • Attained a projected savings of $586K over a 12-month period
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