Flexible machining environments - tests on the shop floor in order to minimize setup times

In previous work the authors proposed a model suitable for reducing the number of cutting tools required for machining in factory environments, where production lots consisting of a small number of pieces of different materials and geometries were optimized. The model, although yielding good results in simulations, lacked a practical application. The purpose of this paper is to analyze and provide any needed modifications of the optimization model and then validate the more recent one using data obtained from its practical implementation in the shop floor of an industry that operates using flexible machining practices. This implementation is important to allow the identification of other situations that were not perceived in simulation, such as the variation in cutting tool life. The results show that the model can be successfully applied to flexible manufacturing environments.