INTRODUCTION TO JIGS AND FIXTURES
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INTRODUCTION TO JIGS AND FIXTURES
The worlds demand for manufactured goods is growing at staggering rate.
Industry has responded with new and radical ways.
Modern / Lean Manufacturing methods:
• Flexible Manufacturing Systems (FMS)
• Just In Time (JIT)
• KANBAN
• Just In Sequence (JIS)
• Total Productive Maintenance (TPM)
• Quick Response Manufacturing (QRM)
• Cellular Manufacturing
• Statistical Process Control (SPC)
• Single Minute Exchange of Dies (SMED) 2
INTRODUCTION TO JIGS AND FIXTURES
Basically, modern manufacturing methods boil down to three key concepts:
•Reduce waste -
•reduce the amount of materials, capacity and manpower wasted in the
process by producing just enough product to meet current demand
•Maintain quality –
•devise more effective manufacturing methods in order to continue making
quality products despite strict reductions of waste
•Accelerate production –
•decrease the amount of time needed to manufacture product, making up
for the lack of surplus 3
INTRODUCTION TO JIGS AND FIXTURES
The changes in the art of manufacturing have created a dire need for more
cost effective and efficient work holding methods and devices.
Despite many advancements and changes in cutting tools, machine tools
and production methods, the basic requirement of holding the workpiece
remained constant.
Every part produced must be held while it is machined, joined or inspected.
The successful running of any mass production depends upon the
interchangeability to facilitate easy assembly and reduction of unit cost.
Mass production methods demand a fast and easy method of positioning
work for accurate operations on it.
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INTRODUCTION TO JIGS AND FIXTURES
Jigs and fixtures
are production tools used to accurately manufacture duplicate and
interchangeable parts.
Jigs and fixtures are specially designed so that large numbers of components
can be machined or assembled identically, and to ensure interchangeability of
components.
Jigs and fixtures are so closely related that the terms are sometimes confused
or used interchangeably.
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INTRODUCTION TO JIGS AND FIXTURES
Jig
• is a special device that holds, supports, and locates the part
accurately or is placed on a part to be machined and the cutting
tool is guided to the specific location during machining
operation on any number of similar work-pieces.
• Jigs are usually fitted with hardened steel bushings for guiding
or other cutting tools.
• a jig is a type of tool used to control the location and/or motion
of another tool.
• A jig's primary purpose is to provide repeatability, accuracy,
and interchangeability in the manufacturing of products.
• A device that does both functions (holding the work and 6
guiding a tool) is called a jig.
INTRODUCTION TO JIGS AND FIXTURES
WING NUT CLAMP
DRILL JIG TOP PLATE
LOCATING PLATE
JIG BUSH
BASE PLATE
V – BLOCK
LOCATOR SIDE CLAMP
COMPONENT
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INTRODUCTION TO JIGS AND FIXTURES
FIXTURE
• It is a work holding device that holds, supports and locates the work piece
for a specific operation but does not guide the cutting tool.
• It provides only a reference surface or a device. What makes a fixture
unique is that each one is built to fit a particular part or shape.
• The main purpose of a fixture is to locate and in some cases hold a work
piece during either a machining operation or some other industrial process.
A jig differs from a fixture in that a it guides the tool to its correct position
in addition to locating and supporting the work piece.
• Fixture should be fastened securely to the work table.
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INTRODUCTION TO JIGS AND FIXTURES
Handle Orientation Cutter
Swing c-
washer
Clamping
element Clamping
force
Angle plate Work piece
Tenon
Base plate
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INTRODUCTION TO JIGS AND FIXTURES
Difference between Jigs & Fixtures
JIG FIXTURES
• It is a work holding device, which • It is work holding device, which
holds and positions the work hold and positions the work piece
piece and guides the cutting tools and does not guide & locate the
to the work piece cutting tool
• It is usually not fixed to the • It is usually fixed to the
machine table ( in case of small machine table
size holes ( less than dia. 6 mm.)
• It is usually light in construction • It is usually heavier in
construction
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INTRODUCTION TO JIGS AND FIXTURES
Difference between Jigs & Fixtures
JIG FIXTURES
• It is usually light in construction • It is usually heavier in
construction
• It is only used for machining • Other than machining operation,
operation it is also used for assembly and
welding, inspection operations
etc.,
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INTRODUCTION TO JIGS AND FIXTURES
WHY THE JIGS & FIXTURES ARE USED
To reduce the cost of production, as it eliminates the laying out of work and
setting up of cutting tools.
To increase the production
To assure high accuracy of the part
To provide for interchangeability
To enable heavy and complex shaped parts to be machined
To reduce the cost of inspection
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INTRODUCTION TO JIGS AND FIXTURES
WHY THE JIGS & FIXTURES ARE USED
To increase the versatility of machine tool
To employ semi-skilled labour
To save labour cost
To partially automate the machine tool
To improve the safety at work, thereby to reduce the rate of accidents.
To improve overall equipment effectiveness (OEE)
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INTRODUCTION TO JIGS AND FIXTURES
DISADVANTAGES OF THE JIGS & FIXTURES
JIG / FIXTURE MAY BECOME OBSOLETE IF THERE IS ANY CHANGE OF
PRODUCT DESIGN
INITIAL DEVELOPMENT TIME
NOT ECONOMICAL IF BATCH SIZE IS VERY LESS
LIMITATIONS IN ACHIEVING THE PART TOLERANCES.
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INTRODUCTION TO JIGS AND FIXTURES
TOOL DESIGN
Tool design is the process of designing and developing the tools , methods and
techniques necessary to improve manufacturing efficiency and productivity.
Since no single tool or process can serve all forms of manufacturing,
Tool design is an ever changing, growing process of creative problem solving.
Tool Design objective
The main objective of tool design is to lower manufacturing costs while
maintaining quality and increased production.
To accomplish this the tool designer must satisfy :
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INTRODUCTION TO JIGS AND FIXTURES
Tool Design objective
• Provide simple, easy to operate tools for maximum efficiency.
• Reduce manufacturing expenses by producing the parts at the lowest
possible cost.
• Design the tools that consistently produce part of high quality.
• Increase the rate of production with existing machine tools.
• Design the tools to make it fool proof and to prevent improper use.
• Select material that gives adequate tool life.
• Provide protection in the design of the tools for maximum safety of the
operator.
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INTRODUCTION TO JIGS AND FIXTURES
Planning the Design
The designer is responsible for managing information resources that impact
the tool design.
Part drawings
Tool designer receives the part geometry
as shown.
Task of the tool design begins with a
more complete understanding of the
part.
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INTRODUCTION TO JIGS AND FIXTURES
Part drawings
While analysing the part drawing, the following factors that directly influence
Design choices.
• Overall shape and size of the part.
• Type and condition of the material used for the part
• Type of machining operations to be performed
• Degree of accuracy
• Number of pieces to be made
• Locating and clamping surfaces
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INTRODUCTION TO JIGS AND FIXTURES
Production plan
The production plan is an itemised list
Of the manufacturing operations and
sequence of the operations.
Tool designer also uses this plan to
Assist in the design
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INTRODUCTION TO JIGS AND FIXTURES
Production plan
The production plan can include the following:
• Type and size of the machine tool specified for each operation.
• Type and size of the cutters specified for each operation.
• Sequence of operations.
• Previous machining operations performed on the part.
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INTRODUCTION TO JIGS AND FIXTURES
Requirements to become a tool designer
• Ability to make mechanical drawings and sketches.
• Understanding of modern manufacturing methods, tools and techniques
• A creative mechanical ability
• Understanding of basic tool making methods
• Knowledge of technical mathematics through practical trigonometry
• CAD model / drafting skills
• File management
• Electronic communication skills
• Geometric dimensioning and tolerancing.
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INTRODUCTION TO JIGS AND FIXTURES
Summary
• Tool design is the process of designing and developing tooling devices, methods and procedures to aid in
Improving overall manufacturing efficiency and productivity.
• The primary objective of tool design is lowering manufacturing costs while maintaining consistent quality
and increased production
• Tool design function is a well integrated position within concurrent engineering team, requiring skills in
computer technology and multiple communication mediums.
• Tool designers use part drawings and production plans in developing alternate design solutions for
efficient, dependable and cost effective tool designs.
• Tool designers, in addition to designing tooling, may also be responsible for toolroom supervision,
procurement and tool inspection.
• To become a tool designer, an individual must be able to make mechanical drawings and sketches,
understand manufacturing techniques and tool making methods and equipment, have a creative
mechanical ability and have a working knowledge of shop mathematics through practical trigonometry.
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INTRODUCTION TO JIGS AND FIXTURES
Fundamental principles of Jigs and Fixtures design
LOCATION:
Good facilities should be provided for locating the job.
The part to be machined must be easily inserted and quickly taken out from
the jig so that no time is wasted in placing the workpiece in position to
perform operations.
The position of workpiece should be accurate with respect to tool guiding in
the jig or setting elements in fixture.
FOOL PROOF:
The design of jigs and fixtures should be such that it would not permit the
workpiece or the tool to inserted in any position other than the correct one.
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INTRODUCTION TO JIGS AND FIXTURES
Fundamental principles of Jigs and Fixtures design
REDUCTION OF IDLE TIME:
Design of Jigs and Fixtures should be such that the process, loading, clamping
and unloading time of the workpiece takes minimum as far as possible.
WEIGHT OF JIGS AND FIXTURES:
It should be easy to handle, smaller in size and low cost in regard to amount
of material used without sacrificing rigidity and stiffness.
JIGS PROVIDED WITH FEET:
Jigs sometimes are provided with feet so that it can be placed on the table of
the machine.
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INTRODUCTION TO JIGS AND FIXTURES
Fundamental principles of Jigs and Fixtures design
MATERIALS FOR JIGS AND FIXTURES:
Wear elements usually made of hardened materials to avoid frequent
damage and to resist wear. Base elements made of soft material.
Example- MS, Cast iron, Die steel, CS, HSS.
CLAMPING DEVICE:
It should be as simple as possible without sacrificing effectiveness.
The strength of clamp should be such that not only to hold the workpiece
firmly in place but also to take the strain of the cutting tool without
springing when designing the jigs and fixtures.
Should not damage the work piece.
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INTRODUCTION TO JIGS AND FIXTURES
Essential features of Jigs and Fixtures
Reduction of idle time –
Should enable easy clamping and unloading such that idle time is minimum
Cleanliness of machining process –
Design must be such that not much time is wasted in cleaning of burrs, chips
etc.
Replaceable part or standardization –
The locating and supporting surfaces as far as possible should be
replaceable, should be standardized so that they are interchangeable and
manufacture is possible
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INTRODUCTION TO JIGS AND FIXTURES
Essential features of Jigs and Fixtures
Provision for coolant –
Provision should be there so that the tool is cooled and the burrs and chips
are washed away
Hardened surfaces –
All locating and supporting surfaces should be hardened materials as far as
conditions permit so that they are not quickly worn out and accuracy is
retained for a long time
Inserts and pads –
Should always be riveted to those faces of the clamps which will come in
contact with finished surfaces of the workpiece so that they are not spoilt
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INTRODUCTION TO JIGS AND FIXTURES
Essential features of Jigs and Fixtures
Fool-proofing –
Pins and other devices of simple nature incorporated in such a position that
they will always spoil the placement of the component or hinder the fitting
of the cutting tool until the latter are in correct position
Economic soundness –
Equipment should be economically sound, cost of design and manufacture
should be in proportion to the quantity and price of producer
Easy manipulation –
It should be as light in weight as possible and easy to handle so that
workman is not subjected to fatigue, should be provided with adequate lift
aids 29
INTRODUCTION TO JIGS AND FIXTURES
Essential features of Jigs and Fixtures
Initial location –
Should be ensured that workpiece is not located on more than 3 points in
anyone plane test to avoid rocking, spring loading should be done
Position of clamps –
Clamping should occur directly above the points supporting the workpiece
to avoid distortion and springing
Clearance –
Sufficient amount of clearance should be provided around the work so that
operator’s hands can easily enter the body for placing the workpiece and
any variations of work can be accommodated
Ejecting devices –
Proper ejecting devices should be incorporated in the body to push the
workpiece out after operation 30
INTRODUCTION TO JIGS AND FIXTURES
Essential features of Jigs and Fixtures
Rigidity and stability –
It should remain perfectly rigid and stable during operation.
Provision should be made for proper positioning and rigidly holding the jigs
and fixtures
Safety –
The design should assure perfect safety of the operator
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INTRODUCTION TO JIGS AND FIXTURES
General rules for designing :
• Compare the cost of production of work with present tools with the
expected cost of production, using the tool to be made and see that the
cost of buildings is not in excess of expected gain.
• Decide upon locating points and outline clamping arrangement
• Make all clamping and binding devices as quick acting as possible
• Make the jig fool proof
• Make some locating points adjustable
• Avoid complicated clamping arrangements
• Round all corners
• Provide handles wherever these will make handling easy
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INTRODUCTION TO JIGS AND FIXTURES
General rules for designing :
• Provide abundant clearance
• Provide holes on escapes for chips
• Locate clamps so that they will be in best position to resist the pressure of
the cutting tool when at work
• Place all clamps as nearly as possible opposite some bearing point of the
work to avoid springing action
• Before using in the shop, test all jigs as soon as made
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Jigs & Fixtures
Design Economics
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INDUSTRY DEMANDS
• Maximum productivity
• Minimal cost
• Consistent quality
• On time delivery
• Zero breakdowns
• Zero defects
• Safety
• Low maintenance cost.
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Principles of design economics.
• Simplicity : Basic and simple design. Keep all designs simple &
uncomplicated.
• Pre-machined / pre-formed materials : where possible use pre-
formed /machined components like tooling plates, brackets,
structural sections.
• Standard components : As for as possible use standard
components like clamps, locators, supports, drill bushings, pins,
screws, bolts, nuts, springs, etc.
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Principles of design economics.
Secondary operations : Eliminate or reduce secondary operations
like heat treatment, Grinding.
Grinding is to be limited to areas that contact parts / machine.
Heat treatment is to be limited to areas that are subjected to wear
such as supports, locators, moving parts.
Avoid secondary machining operations that do not directly affect the
accuracy of the tool.
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Principles of design economics.
• Tolerance: Don’t use very close tolerance than required.
• Generally 20% to 50% of the part tolerance is the tolerance
of the tool.
• More than required is wasteful and adds to the cost of the
tool
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Principles of design economics.
Simplified drawings :
• standard parts are drawn for clarity but not for details.
• Avoid unnecessary views / projections / details.
• Use more symbols.
• Do not oversimplify—required information is to be given.
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Economic Analysis
• Tooling estimate : estimate the cost of the tool.
• Projected savings over alternate methods / tools.
• Justify the cost ---close tolerance, high volume production.
• Estimate the cost of material and labor.
• Number of parts per hour.
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Tool cost & productivity
• Total cost of material & labor to make the tool is to be estimated.
• Prepare a part list of the tool assembly.
• Prepare a process sheet which includes all operations for each part.
• Prepare a cost sheet for each part.
• Estimate the tool cost
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Estimation
• Calculate production rate i.e.: the number of parts / hour the tool can
produce
• Estimate the cost per part.
• Estimate the labor cost
• Parts / hr.= 1 / machining time + loading & unloading time.
E.g. : machining time = 0.25 hrs.
loading time = 0.1hr.
unloading time = 0.1hr.
Total = 0.45hrs.
Parts/hour = 1 / 0.45 = 2.22 parts / hr. 42
Estimation of labor cost.
lot size
Cost of labor = x wages per hr
parts per hr
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Example.
4000 parts to be milled using a fixture.
Tool can produce 60 parts per hour.
Operator wages is Rs.25.00 per hour.
Find the labor cost for the lot.?
lot size
Cost of labor = x Wages / hour
parts / hour
4000
Cost of labor = x 25
60
Cost of labor = 1666.67 Rs
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Estimate the cost per part
What is the cost per part in a milling operation if
the lot size is 4000,
fixture cost is Rs.10,000,
cost of labor is [Link] the lot.?
Cost per part. Tool cost + cost of labor.
=
Lot size.
10000 + 1666.5
Cost per part. =
4000
= Rs. 2.92
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Calculate the savings
In previous example, if
• With out fixture cost per part.= Rs.5.92
• With fixture cost per part. = Rs.2.92
• Savings per part = 5.92-2.92 = Rs. 3.00
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Break – Even Point (ROI)
• Number of parts produced by the tool to pay for itself.
• After recovering the tool cost the parts produced will be free of
tool cost and this adds to the profit.
Tool cost
BEP =
Savings per part
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Example.
• What is the break-even point in a milling operation
Using a fixture costing Rs.10,000
• Cost per part with fixture is Rs.2.92
• Cost per part without fixture is Rs,5.92
Tool cost
BEP =
Savings per part
= 10000/3
= 3333.33 48
Comparative
• Compare cost versus savings.
• Select tool which returns fast.
• Break-even point is the minimum number of parts
a tool must produce to pay for itself.
• Prepare a work sheet and find out which alternate
tool will produce minimum number of parts to pay
for itself.
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Work sheet example.
Economic With out fixture. With fixture-1 With fixture-2
factor.
Lot size 500 500 500
Tool cost ----- RS.3500 Rs.11000
Out put –parts 15 30 120
per hour.
Wages per hour Rs.12 Rs.12 Rs.12
Labor cost for Rs.400 Rs.200 Rs.50
the lot.
Labor cost per Rs.0.80 Rs.0.40 Rs.0.10
part.
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Break-Even Point.
BEP = tool cost / savings
Rs.3500 / Rs.0.4 = 8,750 Nos.---fixture-1
Rs.11000 /Rs. 0.7 = 15,714.28 Nos-fixture-2
BEP = 8,750 Nos.
Below BEP = Loss Above BEP = Profit.
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Design Economics
Factors in determining the design of jig /
fixture
Number
The cost of parts
of the to be
tool. produced.
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Small quantity • Simple, low cost tool
of parts to be may be satisfactory.
produced.
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Necessity
Determines
the type of
Reducing jig/ fixture
the present is to be
cost of an made.
Keeping the existing
[Link] of part.
a new part
as low as
possible.
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In some cases the cost
of an operation may
be reduced by using a
more efficient though
more expensive tool.
• Through the use of a more
Increased accuracy elaborate tool frequently
and
warrants its greater cost.
interchangeability.
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The use of jig / fixture
Only after justifying the cost of the component
by using jig / fixture in comparison of other
process of making the component.
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Method of finding the cost / component using
jig/fixture and conventional process.
K1 = cost / piece without jig/fixture
K2 = cost / piece with jig / fixture
T1 = cost of tooling(standard/simple)
T2 = cost of jig / fixture.
n = number of pieces to be made.
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Total cost without tooling = x1 = (n x K1) + T1
Total cost with special tooling = X2 = (n x K2) + T2
For economy of employing a jig/fixture the condition must be that
For economy of employing a jig/fixture the condition must be that X2 must be less than X1,(X2 < X1)
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• The minimum number of components required for the
production can be found out from the equation when X2 = X1.
• (n x k1)+T1 = (n x k2)+T2
• (n x k1)-(n x k2) = T2-T1
• n (k1-k2) = T2-T1
• n =(T2-T1) / (k1-k2)
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Exercise
• What could be the cost of drill jig for 1000 pieces
when k1=0.95,
k2=0.40,
T1=500/-
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Exercise
• n= (T2-T1) / (k1-k2)
• (T2-T1) = n (k1-k2)
• T2 = n (k1-k2)+T1
• 1000(0.95-0.4)+500
• (1000x0.55) + 500
• 550+500
• 1050
• Rs. 1050
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BEP
Tool cost
BEP =
Savings per part
• BEP = T2 / (k1-k2)
• 1050 / 0.55
• 1909 nos.
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Example 1:
Five thousand parts are to be milled using a fixture capable of producing 60 parts per
hour.
What is the cost of labour if the machine operator earns Rs. 25 per hour?
lot size
Cost of labor = x wages per hr
parts per hr
5000
Cost of labor = x 25
60
= 2083
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Example 2:
What is the cost per part of a milling operation for 7000 parts when the
fixture costs Rs. 3850 and the labour expense is Rs. 54000?
Cost per part. Tool cost + cost of labor.
=
Lot size.
Cost per part. 3850 + 54000
=
7000
Cost per part. = Rs. 8.26
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Example 3: A lathe fixture costs Rs 10500 to build and produces parts at a
cost of Rs 14 . How many parts must it produce to pay for itself when
compared to an alternate method that requires no special tooling and is
capable of making the parts at a cost of Rs 28 each?
BEP = T2 / (k1-k2)
= 10500 / (28-14)
= 750 nos.
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COMPARATIVE ANALYSIS
The tool designer must consider and evaluate several options before making
a tooling recommendation to management.
By comparing each method, he can see the tooling requirements in terms of
costs versus savings.
Then the method that returns the most for each Rupee spent can be
selected.
When preparing this comparison, the tool designer must weigh all the
economic factors in relation to expenses and productivity.
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COMPARATIVE ANALYSIS
Example: Five hundred guide plates must be milled.
The tool designer has determined three possible alternatives:
1. Have a toolmaker, who earns Rs. 840 per hour, mill the plates at a rate of
25 per hour.
2. Use limited tooling that costs Rs. 2450 in the production department. The
machine operator in this department, who earns Rs. 490 per hour, can
make a part every 1.33 minutes. (1 minute 20 seconds)
3. Use a more expensive tool that costs Rs. 7700 but is capable of producing
a part every 24 seconds.
This would be done in the production department, where a machine
operator earns Rs. 490 per hour.
Which is the best option? 67
COMPARATIVE ANALYSIS
Comparison work sheet
Economic factor. Alternative -1 Alternative -2 Alternative -3
Lot size 500 500 500
Tool cost 0 RS.2450 Rs.7700
Out put –parts 25 ? ?
per hour.
Wages per hour Rs.840 Rs.490 Rs.490
Labor cost for ? ? ?
the lot.
Cost per part. ? ? ?
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COMPARATIVE ANALYSIS
The first values that should be calculated are the parts per hour:
1 hour
Parts per hour =
Cycle time for one part
1. For alternative 1, given parts per hour = 25
2. For alternative 2, = 1/ 1.33 minutes = 1/ 1.33/60 = 45
3. For alternative 3, = 1/ 24 seconds = 1/ 24/3600 = 150
lot size
The next calculation is cost of labour: Cost of labor = x wages per hr
parts per hr
1. For alternative 1, = 500 x 840 / 25 = 16,800 Rs
2. For alternative 2, = 500 x 490 / 45 = 5444 Rs
3. For alternative 3, = 500 x 490 / 150 = 1633 Rs
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COMPARATIVE ANALYSIS
The next is cost per part :
Tool cost + cost of labor.
Cost per part. =
Lot size.
1. For alternative 1, = 0+ 16800 / 500 = 33.6 Rs
2. For alternative 2, = 2450 + 5444 / 500 = 15.788 Rs
3. For alternative 3, = 7700 + 1633 / 500 = 18.666 Rs
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COMPARATIVE ANALYSIS
Comparison work sheet
Economic factor. Alternative -1 Alternative -2 Alternative -3
Lot size 500 500 500
Tool cost 0 RS.2450 Rs.7700
Out put –parts 25 45 150
per hour.
Wages per hour Rs.840 Rs.490 Rs.490
Labor cost for Rs 16800 Rs 5444 Rs 1633
the lot.
Cost per part. Rs 33.6 Rs 15.8 Rs 18.7
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COMPARATIVE ANALYSIS
Conclusion Economic
factor.
Alternative -1 Alternative -2 Alternative -3
Lot size 500 500 500
The first alternative saves the cost of tooling, but because of the Tool cost 0 RS.2450 Rs.7700
slow production rate and high labour cost, the savings are lost. Out put –
parts per
hour.
25 45 150
This method may be useful for a small run of fewer than 50 Wages per
hour
Rs.840 Rs.490 Rs.490
parts or for experimental production purposes. Labor cost
for the lot.
Rs 16800 Rs 5444 Rs 1633
When cost is the only factor, the first alternative is not suitable. Cost per part. Rs 33.6 Rs 15.8 Rs 18.7
The third alternative produces the parts at a higher production rate and a lower labour
cost than do the other alternatives.
The savings are again offset, this time by the tool cost.
If the production run were greater, this method would be the least expensive.
For the lot size specified, the third alternative is too costly.
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COMPARATIVE ANALYSIS
Conclusion Economic
factor.
Alternative -1 Alternative -2 Alternative -3
Lot size 500 500 500
Tool cost 0 RS.2450 Rs.7700
Out put – 25 45 150
parts per
hour.
The second alternative has the lowest cost per Wages per
hour
Rs.840 Rs.490 Rs.490
part of the three alternatives and will return the most
Labor cost Rs 16800 Rs 5444 Rs 1633
for the lot.
Cost per part. Rs 33.6 Rs 15.8 Rs 18.7
for each Rupee invested.
For these reasons, it is the alternative the tool designer
should select.
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