Optimization of Cutting Tool Life of Tensile Test Specimens Through Kaizen Application of Milling Jig Height Redesign

Abstract

The use of cutting tools in the CNC milling process is often not optimal because wear only occurs on the bottom of the cutting edge, while most of the cutting edge is still usable. This condition increases tool consumption, production downtime, and operational costs. This study aims to optimize the service life of cutting tools through the application of Kaizen by redesigning the height of the milling jig. The study used a descriptive qualitative approach with the Kaizen method through the Plan-Do-Check-Act (PDCA) cycle. The study population was the entire process of making tensile test specimens using a CNC milling machine at the Material Testing Laboratory of Pelita Bangsa University, while the sample was selected by purposive sampling in processes that experience wasteful use of cutting tools. The research instruments included observation sheets, documentation, jig dimension measuring tools, and tool usage records. Data analysis was carried out descriptively by comparing conditions before and after the implementation of Kaizen. The results showed that the redesign of the milling jig was able to shift the cutting area to the part of the cutting edge that was still sharp so that the service life of the cutting tool increased by about 50 percent and the consumption of new tools decreased by 50 percent without reducing the quality of the machining results. This study concludes that the application of Kaizen through simple modifications to the milling jig is an effective and low-cost solution to increase the efficiency of cutting tool use and support continuous improvement in the manufacturing process.