0 results

MILLING INDUSTRIES CREATING UNIQUE ALUMINIUM

Milling Industries Creating Unique Aluminium

A leading global aluminium manufacturer partnered with ALTEN to deliver high-precision aluminium building kits for industries such as yachting and shipbuilding. By leveraging advanced dry milling, 5-axis machining, automation, and data-driven insights, ALTEN helped optimize manufacturing efficiency, sustainability, and cost effectiveness—while maintaining the highest quality standards.

Challenge:

  • High dependency on manual processes, increasing error rates and estimation inaccuracies
  • Need for process optimization to offset the cost of advanced manufacturing techniques
  • Achieving sustainability goals without compromising safety, performance, or compliance
  • Demand for accurate cost estimation in a competitive, margin-sensitive market

Solutions

Advanced Milling Techniques:

  • Implementation of dry milling and 5-axis 3D milling for complex, high-precision aluminium parts
  • Elimination of heat input, preventing material shrinkage and weakening

Process Automation & Optimization:

  • Automated nesting and systematic material utilization to reduce waste
  • Direct milling of weld edges and rejuvenations to speed up downstream welding processes

Digital Enablement & Data-Driven Decisions:

  • Sensors integrated with Power BI for predictive maintenance and real-time visibility
  • Python-based scripting to automate workflows and reduce manual effort

End-to-End Integration:

  • Seamless integration between engineering, manufacturing, estimation, and procurement tools
  • QR code–enabled traceability for parts, certificates, and documentation via a secure cloud platform

Benefits

  • 15–20% reduction in manual effort and production time
  • 10–15% overall cost savings through optimized estimation and material usage
  • Significant reduction in errors and rework
  • Improved material utilization and remnant reuse
  • Up to 30% construction time savings compared to conventional techniques

Knowledge Where It Counts

  • Reduced manual intervention directly improves estimation accuracy and cost control
  • Dry milling preserves aluminium integrity while supporting sustainability goals
  • 5-axis machining enables flexible, complex designs not achievable with conventional methods
  • Real-time analytics through Power BI supports ROI-driven decisions and continuous improvement

Tools & Technologies

  • Manufacturing & CAM: SolidCam, AlmaCam
  • Analytics & Automation: Power BI, Python
  • Shop Floor Systems: Isah Shop Floor
  • Digital Infrastructure: Sensors, Cloud-based document management, QR code traceability