The Situation

This major international automotive supplier faced significant challenges related to tool life, impacting their production efficiency and causing machine downtime. The custom tool they were using was producing 1,500 parts, but consistently falling short of the target. The existing cycle time of 15 seconds and a feed per revolution of .0060” were contributing to the inefficiencies.

Current Process Results


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  • Competitor’s custom carbide step drill
  • 15 second cycle time
  • 0.0060” feed per revolution
  • 1,500 parts per tool
  • $350/tool
  • $525,000 total tool cost

New GWS Solution


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  • Custom carbide step drill
  • 13 second cycle time (15% cycle reduction)
  • 0.0100” feed per revolution
  • 3,000 parts per tool
  • $380/tool
  • $285,000 total tool cost
  • $240,000 Total Tool Cost Savings

Conclusion

Upon turning to GWS for a solution to address the shortcomings of the competitor’s custom step drill, a comprehensive problem-solving approach was initiated. GWS undertook the development of three prototypes in the pursuit of the optimal cutting tool. Through testing and refinement, a cutting-edge tool was identified, enabling the supplier to consistently achieve a production volume of 3,000 parts per tool. Additionally, the feed per revolution was increased to 0.0100”, leading to a significant reduction in cycle time from 15 seconds to just 13 seconds. This improvement directly addressed the issue of machine downtime, enhancing overall operational efficiency.

Despite the initial higher cost of the custom tool provided by GWS, the results were remarkable. The optimized tool not only met the production quota but also extended the tool life by an impressive 100%. This increase in tool lifespan resulted in substantial cost savings, with the total annual tool cost plummeting from $525,000 to $240,000.

Interested in finding out more information about our standard and custom tools? Consider contacting the experts who make Custom Come Standard, and let us find the perfect cutting tool for you. Just send us an email at sales@gwstoolgroup.com to get started!


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