Calculating 5-Axis Part Savings

You have jobs today that you are flipping parts as part of the machining operation because they are multi-sided or have holes at an angle.
Ever wonder how much time you could save by moving those parts to a 5-axis machine and eliminating all those setups and flips?
Use the sheet below to figure out how much time you could save and profit you could make, if you switched to a 5-sided process.

Step 1: Pick a part you want to use and enter the current setup, load and cycle times (don't forget all the special fixturing time too)
Step 2: Enter your assumptions for shop rate, tool optimization, and batch size
Step 3: Estimate the setup and load times if this part was done on a 5-axis machine which is typically one or two operations. Cycle time calcuates as the 3-axis cycle time minus your tool optimization savings.
Step 4: Check out the savings you would realize by moving to 5-axis money that could be going back into your pocket.

Assumptions

Shop Rate Per Hour $ 60 Enter your shops hourly rate

Tool Optimization 25% Enter the expected tool change time savings for 5-axis which typically ranges from 20-30%. Try zero to start with if you want the most conservative estimate.
Batch Size 10 Enter the number of parts you expect to run in a batch

Current 3-Axis Operation 5-Axis Scenario

Setup Time Load Time Cycle Time Setup Time Load Time Cycle Time
Operation (Mins) (Mins) (Mins) Description of Operation Operation (Mins) (Mins) (Mins) Description of Operation
1 30 0.3 4.0 Drill top holes and counter bore 1 30 0.3 Drill, counter bore top side
2 30 0.3 0.7 Facemill back side 2 60 0.3 Complete the rest of the part
3 30 0.3 1.1 Facemill front and mill pocket
4 30 0.3 2.5 Mill, drill, and notch right side
5 30 0.3 2.4 Mill and drill left side
6 90 0.3 5.1 Mill front, drill / counter bore - built fixture
7 90 0.3 4.1 Mill back angle - built fixture to cut angle
8
9
10
Total All Operations 330 2.1 19.8 Total All Operations 90 0.6 14.8

Batch Size 10 Batch Size 10

Total Batch Cost $ 549 Total Batch Cost $ 244
Cost Per Part $ 54.87 Cost Per Part $ 24.43

5-Axis Benefit
Increase in Profit $ 304 55%
Part Margin Increase $ 30.44
Calculating 5-Axis Part Savings

You have jobs today that you are flipping parts as part of the machining operation because they are multi-sided or have holes at an angle.
Ever wonder how much time you could save by moving those parts to a 5-axis machine and eliminating all those setups and flips?
Use the sheet below to figure out how much time you could save and profit you could make, if you switched to a 5-sided process.

Step 1: Pick a part you want to use and enter the current setup, load and cycle times (don't forget all the special fixturing time too)
Step 2: Enter your assumptions for shop rate, tool optimization, and batch size
Step 3: Estimate the setup and load times if this part was done on a 5-axis machine which is typically one or two operations. Cycle time calcuates as the 3-axis cycle time minus your tool optimization savings.
Step 4: Check out the savings you would realize by moving to 5-axis money that could be going back into your pocket.

Assumptions

Shop Rate Per Hour $ 60 Enter your shops hourly rate

Tool Optimization 25% Enter the expected tool change time savings for 5-axis which typically ranges from 20-30%. Try zero to start with if you want the most conservative estimate.
Batch Size 10 Enter the number of parts you expect to run in a batch

Current 3-Axis Operation 5-Axis Scenario

Setup Time Load Time Cycle Time Setup Time Load Time Cycle Time
Operation (Mins) (Mins) (Mins) Description of Operation Operation (Mins) (Mins) (Mins) Description of Operation
1 60 0.3 2.3 Face, drill center h ole, mill OD profile 1 30 0.3 Drill, counter bore top side
2 30 0.3 1.0 Face, drill thru, mill c'bore, mill notch 2 60 0.3 Complete the rest of the part
3 30 0.3 1.0 Face, mill c'bore
4 30 0.3 0.8 Face, mill (3) ribs
5 0 0.3 0.8 Face, mill (3) ribs
6 90 0.3 1.3 Mill right angle & drill
7 0 0.3 1.3 Mill left angle & drill
8 90 0.3 0.5 Mill front agle & drill
9
10
Total All Operations 330 2.4 8.8 Total All Operations 90 0.6 6.6

Batch Size 10 Batch Size 10

Total Batch Cost $ 442 Total Batch Cost $ 162
Cost Per Part $ 44.15 Cost Per Part $ 16.16

5-Axis Benefit
Increase in Profit $ 280 63%
Part Margin Increase $ 27.99
Calculating 5-Axis Part Savings

You have jobs today that you are flipping parts as part of the machining operation because they are multi-sided or have holes at an angle.
Ever wonder how much time you could save by moving those parts to a 5-axis machine and eliminating all those setups and flips?
Use the sheet below to figure out how much time you could save and profit you could make, if you switched to a 5-sided process.

Step 1: Pick a part you want to use and enter the current setup, load and cycle times (don't forget all the special fixturing time too)
Step 2: Enter your assumptions for shop rate, tool optimization, and batch size
Step 3: Estimate the setup and load times if this part was done on a 5-axis machine which is typically one or two operations. Cycle time calcuates as the 3-axis cycle time minus your tool optimization savings.
Step 4: Check out the savings you would realize by moving to 5-axis money that could be going back into your pocket.

Assumptions

Shop Rate Per Hour $ 60 Enter your shops hourly rate

Tool Optimization 25% Enter the expected tool change time savings for 5-axis which typically ranges from 20-30%. Try zero to start with if you want the most conservative estimate.
Batch Size 10 Enter the number of parts you expect to run in a batch

Current 3-Axis Operation 5-Axis Scenario

Setup Time Load Time Cycle Time Setup Time Load Time Cycle Time
Operation (Mins) (Mins) (Mins) Description of Operation Operation (Mins) (Mins) (Mins) Description of Operation
1 1
2 2
3
4
5
6
7
8
9
10
Total All Operations 0 0.0 0.0 Total All Operations 0 0.0 0.0

Batch Size 10 Batch Size 10

Total Batch Cost $ - Total Batch Cost $ -
Cost Per Part $ - Cost Per Part $ -

5-Axis Benefit
Increase in Profit $ - #DIV/0!
Part Margin Increase $ -