In today’s competitive manufacturing industry, customers demand high-quality products delivered quickly and efficiently. Manufacturers can use jigs and fixtures, specialized devices that streamline manufacturing processes and ensure consistent results. Jigs and fixtures support machining and assembly operations, helping manufacturers achieve precision, repeatability, and productivity.
Jigs and fixtures can be designed and customized for specific manufacturing processes in the automotive, aerospace, electronics, and woodworking industries. They can be made from different materials, such as steel, aluminum, or plastic, and range in complexity from manual tools to highly automated systems.
Manufacturers can optimize production processes, improve efficiency, and meet customer quality demands using jigs and fixtures.
In this guide, the engineers at Carr Lane Mfg. outline the benefits of integrating these valuable tools into manufacturing processes.
Increased Production
Jigs and fixtures offer several benefits that streamline manufacturing and enhance productivity. They can automate drilling or cutting processes, which increases manufacturing speed and efficiency.
The precise guidance and support provided improve machining accuracy, reducing errors, scrap, and rework, resulting in higher yield and increased production.
Jigs and fixtures offer repeatability, providing consistent results and reducing the likelihood of defects, leading to higher product quality and less time wasted fixing mistakes. Production rates increase by reducing setup and idle time.
Decreased Manufacturing Costs
Reduced errors and defects translate into lower scrap and rework rates, saving manufacturers significantly on materials and labor costs. Jigs and fixtures are manufactured to exact specifications every time, resulting in more efficient use of materials. Automating manual tasks eliminates the need for manual labor, reduces the risk of human error, and increases productivity.
Improved Product Consistency
The high precision and accuracy result in the consistent quality of manufactured components. Using these eliminates the need for manual alignment and adjustment, which can lead to variations in the manufacturing process.
Human error is a common cause of workpiece defects in the manufacturing process. Jigs and fixtures reduce the likelihood of human error by guiding tools and work-holding devices into the correct position.
Improved Assembly Line Safety
Reducing manual handling and machining tool operation helps eliminate the risk of worker accidents and injuries.
Manual handling and tool operation can be hazardous, especially when working with heavy or complex parts. Jigs and fixtures reduce the risks associated with tool operation by providing a secure and stable platform to hold and support.
For example, jigs and fixtures can be equipped with safety guards to protect workers from moving parts and machinery. Additionally, jigs and fixtures can guide the cutting tool, which reduces the risk of accidental part movement or detachment.
Reduced Non-Productive Hours
Jigs and fixtures offer an advantage in streamlining production processes and reducing the time required to set up and adjust machinery. Overall Equipment Effectiveness (OEE) is a metric used to measure the productivity of manufacturing equipment. Jigs and fixtures can improve OEE by efficiently using manufacturing equipment, reducing non-productive hours, and increasing production efficiency.
Reasonable Automation Capabilities
Jigs and fixtures offer reasonable automation capabilities, enabling manufacturers to automate manufacturing processes. Automating repetitive tasks reduces the risk of errors and defects and increases output while reducing labor costs. Manufacturers can benefit from automation capabilities to streamline their operations and improve productivity.
Interchangeability and Accuracy
Manufacturers can achieve higher levels of accuracy and standardization in their manufacturing processes, leading to improved product quality and ease of assembly. Jigs and fixtures ensure the interchangeability of components, reducing variations in production and ensuring consistent fit and function of manufactured parts.
Challenges and Limitations of Jigs & Fixtures
Design and setup require specialized skills and expertise. Manufacturers must understand CAD software, CNC programming, 3D printing, and metrology. This challenge can be overcome through employee training programs or outsourcing to third-party service providers.
The initial investment costs can be significant, especially for small and medium-sized businesses. To address this challenge, manufacturers can explore different financing options to spread the costs over time.
Jigs and fixtures may only suit some manufacturing processes, particularly those involving flexible materials or irregularly shaped parts. In such cases, manufacturers can consider alternative solutions such as automation or robotics or adapt and modify existing jigs and fixtures to suit their needs better.
Unlocking Efficiency and Precision with Jigs and Fixtures
Initial costs and the need for specialized skills can be significant barriers. Proper planning and training help mitigate these challenges.
Carr Lane Mfg. offers components designed to meet the specific needs of our customers’ machining operations. Manufacturers can enhance their competitiveness and succeed more by investing in the proper jigs and fixtures. Explore all of the tools in our product catalog.