Reducing Machine Downtime with Efficient Swarf Management

In manufacturing, even small inefficiencies can lead to significant downtime, and one of the often-overlooked culprits is swarf — (filings, shavings, metal chips or turnings) from machining processes. Poor swarf management can clog systems, damage tools, and slow production.

In this article, we'll explore how efficient swarf handling can drastically reduce machine downtime. You'll learn about best practices, practical solutions, and strategies to streamline swarf management, ultimately boosting productivity and improving operational efficiency in your facility.

best practices for managing swarf:

Segregation of Swarf

Material Separation: Segregate swarf by material type and grade (e.g., steel, aluminium, brass) to facilitate recycling, reduce contamination and improve the value (e.g. cost per tonne).

Dry vs. Wet Swarf: Separate wet swarf (mixed with coolant or lubricants) from dry swarf. Wet swarf requires different processing due to the presence of liquids. For best practice, it is recommended you have a bund underneath a swarf skip to capture the coolant or lubricants. 

Efficient Collection Systems

Centralised Collection: Implement a centralised swarf collection system to gather waste directly from machining operations.

Conveyor Systems: Use conveyors, augers, or vacuum systems to automate swarf collection, minimising manual handling and reducing spillage.

Bins and Hoppers: Provide strategically placed swarf bins or hoppers near machining centres for easy disposal and transfer. Use clear signage to help staff correctly place the swarf. 

Coolant and Lubricant Recovery

Centrifugation or Briquetting: Use swarf centrifuges or briquetting machines to recover coolant and lubricants from wet swarf. These processes can also compact the swarf, reducing its volume for storage and transport.

Coolant Filtration: Implement coolant filtration systems to remove fine swarf particles from recirculating coolants, improving machine performance and extending coolant life. Lack of filtration can lead to blockages in the machine pipework. 

Coolant Recovery Systems: Retro fitting a system to recover coolant from the swarf bin to reduces the need for coolant recovery at a later stage and puts coolant back in to the machine which saves helps to save on coolant costs. 

Recycling

Partnership with Recycling Companies: Establish partnerships with metal recycling companies to collect and process swarf regularly.

Maximise Value: Clean, segregated swarf can be sold at a higher value, so ensure proper handling to maximise recycling profits.

The image shows Metal Swarf being stored onsite, ready to be collected for recycling.

Health and Safety Measures

Dust and Fume Control: Ensure swarf management does not create airborne metal particles or dust. Use proper ventilation or extraction systems.

Personal Protective Equipment (PPE): Ensure workers wear appropriate PPE, such as gloves, eye protection, and cut-resistant clothing, to avoid injuries when handling swarf.

Fire Safety: Metal swarf (especially from materials like magnesium or titanium) can be flammable. Ensure proper fire safety protocols are in place.

Waste Minimisation

Lean Manufacturing Practices: Implement lean manufacturing techniques to minimise waste at the source, reducing the overall volume of swarf.

Tool Optimisation: Optimise cutting tools and processes to improve the chip control. This will help increase tool life by reducing the heat on the cutting tool and putting it in to the swarf. Better chip control prevents coolant from being dispersed by stringy swarf (birds-nesting), this can also have an impact on the running of the chip conveyor and swarf storage at later stages in the swarf management process. 

Automation and Monitoring

Automated Swarf Removal: Most CNC machines have automated swarf removal systems. Consider integrating this technology into your facility to enhance efficiency. When purchasing new machines, it is always worth considering swarf management controls as part of the purchasing criteria. 

Monitoring Systems: Use IoT and other monitoring systems to track swarf production and collection, ensuring timely maintenance and emptying of collection systems. Other systems such as machine monitoring can track how much time operators spend managing swarf from their machine(s).

Tracking the amount of machine downtime caused by Swarf management can help identify where process changes can be made, leading to improved machine uptime.

The image shows a machine operator logging 'Swarf Management' as the reason for the machine downtime. 

The importance of knowing how much time is spent managing Swarf

The time a manufacturer spends managing swarf can vary widely depending on several factors, including the size of the operation, the volume of swarf generated, the complexity of the machining processes, and the level of automation in place.

However, based on information from manufacturers we work with, as well as information available on the web, it would be fair to say that typical estimates can be broken down as follows:

Manual vs. Automated Systems

Manual Handling: In facilities where swarf is collected manually, operators may spend several hours each day dealing with collection, segregation, and transport to disposal areas. This could amount to 5–15% of an operator’s time depending on the volume of swarf, the number of machines and the material removal rate.

Automated Systems: With automated swarf management systems (e.g., conveyors, augers, or vacuum systems), time spent on swarf management can be reduced dramatically. In highly automated plants, swarf management might require less than 1–2 hours per week for system maintenance and oversight.

Size and Scale of Operation

Small to Medium Manufacturers: In smaller facilities, swarf management might take up 1–2 hours per shift, especially if operators are responsible for managing swarf on an ad-hoc basis in addition to their regular tasks.

Large Manufacturers: In larger operations with multiple machining centres, swarf management can become more complex and time-consuming. Without automation, dedicated teams may spend up to 10–20% of their working hours handling swarf. However, many large facilities implement systems to minimise the need for manual intervention.

Frequency of Swarf Removal

High-Volume Machining: In facilities with high-volume production or a high material removal rate, swarf can accumulate quickly. Some manufacturers need to empty collection bins or clean systems multiple times per shift, leading to significant time spent on swarf management.

Low-Volume Machining: For low-volume production, swarf management might only require attention once per day or per shift.

Impact of Lean Practices

Manufacturers that implement lean management practices for swarf handling can reduce unnecessary steps and improve efficiency. In these setups, the time spent on managing swarf may be streamlined significantly, especially if swarf removal and recycling are integrated into the production workflow.

How Swarf can cause unproductive machine downtime

Swarf management can be a significant cause of machine downtime in manufacturing, especially in facilities with high machining volumes or high material removal rates. Therefore, having tools and processes to monitor how much swarf management costs you (time & money) is critical to ensuring it doesn’t become an issue within shop floor operations.

Causes of Downtime Due to Swarf, include:

Clogged Coolant Systems: Excess swarf can block coolant flow, causing cutting tools to overheat or operate inefficiently. This can lead to stoppages for cleaning or maintenance and increased tooling costs.

Swarf Build-up in Machines: If the swarf is not cleared regularly, it can accumulate around the cutting area, leading to reduced cutting precision, tool wear, or even mechanical failure.

Increased Tool Wear and Breakage: Swarf left in the machining area can damage cutting tools, increasing wear, leading to frequent tool changes.

Manual Cleaning and Removal: Operators may need to stop machines frequently to manually remove the swarf, resulting in productivity losses.

How to Improve Swarf Management to Reduce Downtime:

Automate Swarf Removal

Conveyor or Auger Systems: Installing conveyor belts or augers that automatically remove swarf from the machine during operation can reduce the need for manual intervention.

Vacuum Systems: Centralised vacuum systems can efficiently clear swarf from machines without interrupting production.

Chip Crushers and Compactors: These can break down swarf into smaller pieces, making it easier to handle and transport. Well sorted swarf can lead to a higher resale value. 

Improve Coolant Filtration and Recovery

Filtration Systems: Installing filters and separators can prevent swarf from clogging coolant systems, improving coolant flow and reducing the frequency of stoppages.

Coolant Recovery: Implementing systems to recover and recycle coolant while filtering out swarf improves machine efficiency and extends coolant life.

Use Swarf and Machine Monitoring Systems

IoT-Based Monitoring: Sensors can detect swarf accumulation in real time and alert operators before it leads to significant issues. These systems can predict when maintenance is required, reducing unplanned downtime.

As we covered earlier in this article, machine monitoring is another system that can be used to help manufacturers understand how much time is spent on swarf management across all machines, shifts and processes.

For example, an aerospace manufacturer that we work with found that Swarf was one of their biggest reasons for machine downtime across their machines. When the business asked operators how much time they thought was spent on managing Swarf, they replied “2-3 minutes”. It was an honest but incorrect answer.

In fact, downtime logged by the same machine operators showed that the average time spent on Swarf management was 12 minutes (nearly six times as much as they had thought). This led to the businesses implementing new Swarf management techniques, resulting in improved machine uptime and freeing up the operators to focus on running their machines.

Automated Alerts: Systems that alert operators when bins are full or swarf is building up help prevent downtime caused by blockages.

Optimise Tool Design and Machining Processes

Chip Breakers and High-Quality Cutting Tools: Using tools designed to break swarf into smaller, more manageable pieces can reduce swarf accumulation.

Machining Strategy: Modifying the cutting process (e.g., optimising speeds and feeds) can help  prevent long, stringy chips that are more likely to cause blockages (birds-nesting).

Regular Maintenance and Preventive Cleaning

Scheduled Cleaning: Incorporate scheduled maintenance for swarf management into production planning to minimise unplanned downtime. Preventive cleaning ensures that machines run efficiently and without disruptions.

Swarf Disposal Procedures: Ensure swarf collection bins are emptied regularly, especially during high-production runs, to prevent overflow and blockages.

Lean Management and Continuous Improvement

5S Methodology: Implement 5S principles (Sort, Set in Order, Shine, Standardise, Sustain) to maintain cleanliness and orderliness in swarf management, reducing the chance of downtime caused by improper swarf disposal.

The image shows the 5s principles. Click here to download our Free 5S Shop floor posters. 

Continuous Improvement: Regularly review and refine swarf handling processes, engaging machine operators in identifying bottlenecks or inefficiencies that can be addressed to reduce downtime.

By improving swarf management through automation, monitoring, and optimised procedures, manufacturers can significantly reduce machine downtime and enhance overall productivity.

Summary

Investing in automation and lean systems can drastically reduce the labour and time required for managing Swarf. By following best practices and deploying appropriate solutions, you can reduce waste, improve safety, and even turn swarf management into a revenue-generating activity through recycling efforts.

Swarf Management - Key takeaways

• Swarf Management Impacts Downtime: Inefficient swarf handling can lead to machine blockages, tool wear, and system failures, contributing to significant downtime in manufacturing operations.

• Automated Swarf Removal Systems: Automation, such as conveyor belts, augers, or vacuum systems, can streamline swarf collection and reduce the need for manual intervention, minimising downtime.

• Coolant Filtration and Recovery: Implementing filtration and recovery systems ensures swarf doesn’t clog coolant lines, improves coolant efficiency, and helps avoid machine stoppages.

• Real-Time Monitoring: IoT and sensor-based systems provide real-time alerts for swarf build-up, allowing for preventive maintenance and reducing the risk of unplanned downtime.

• Swarf Handling: Optimising tool design, employing chip breakers, and incorporating scheduled maintenance and cleaning can significantly improve swarf management efficiency.