Case Studies
Large Customer, Many Parts
At our largest customer, we “studied” 21 different parts. Some were large, complex weldments in excess of 1,000 pounds. On average, the parts used 20-25 tools of different lengths and sizes. Multiple operations on each section of the parts and processes were reviewed. Once the initial study was complete, we submitted a new tool list to the engineering department with new cycle times and prices. Upon approval to test, we headed back out to the floor and started the initial testing of our proposed process. With each successful test, engineering would approve the change and we would move on to the next part. Our detailed analysis and testing resulted in cost savings of over $500,000, shortened cycle times, increased part quality, and standardized tooling of all the parts studied.
Simple Change, Big Savings
One of the simplest changes we recommended was a cast iron casting for a customer in Minnesota. They were using a carbide insert. We analyzed the grade of the cast iron and the machine tools parameters. Once we were satisfied that it would handle the new speed and feed, we were given the green light to test. We recommended a ceramic insert and lowered cycle time by 2/3rds with the same price tool and doubled tool life. This idea was expanded to several other cells in the plant and we generated a cost savings that totaled over $305,000.
Specific Goals of Increased Speed
At an engine block manufacturer in Springfield, the customer had very specific goals. We started with an evaluation of their current process, questions about the machines’ capabilities and what they wanted to achieve. The new tool we recommended saved them valuable machining time in the slowest part of their manufacturing process or “bottleneck”. By implementing the new tooling we increased production of the line and saved the customer $150,000.
These are just a few samples of our many success stories. Let us help yours become the next!
