Reaming process improvement and control: an application of statistical engineering

This study explores the application of statistical engineering techniques to improve and control the reaming process within the context of small batch production. The objective is to address the challenges faced in meeting dimensional and surface finish tolerances for steel bushings produced on low-cost machine tools. Utilizing a systematic problem-solving approach, the methodology encompasses a comprehensive experimental investigation into the various parameters influencing bore quality, including reamer properties, process parameters, and machine tool signatures. The results reveal substantial opportunities for process enhancement, highlighting the effects of single and combined parameters on both surface finish and bore geometry. Improved understanding of these influences led to better process control, resulting in significantly improved outcomes without incurring additional costs. The findings emphasize the importance of selecting the appropriate machine tools based on technical and economic considerations, ensuring production within the specified conformance zones. This research contributes valuable insights into optimizing manufacturing processes in job shop environments.