A leading manufacturer of power tools for the automotive industry faced increasing pressure to cut production costs while maintaining the high quality and precision required in their components. One specific challenge involved a key component of their tools, where both tooling costs and cycle times had become areas of concern. To remain competitive and meet growing demands, the manufacturer sought a solution that would reduce tooling costs, streamline operations, and ultimately improve their overall efficiency.

Martin’s expert team evaluated the manufacturer’s existing cutting processes and tooling and identified several opportunities for improvement. The existing process relied on a solid .750 milling head, which was effective but costly in terms of both tooling expenses and labor time. To address this, we recommended switching to an indexable carbide solution, which would provide more flexibility and reduce the frequency of tool changes.

In addition to the tooling change, we made specific recommendations on cutting parameters, optimizing speeds and feeds to further improve efficiency and reduce cycle times. These adjustments allowed for smoother operations, less downtime, and extended the life of the tooling used, adding significant value to the manufacturing process.

• By transitioning to the indexable carbide milling solution, the manufacturer achieved tooling cost savings of $97,000 annually.
• Optimized cutting parameters reduced labor costs by $50,000 by shortening cycle times and minimizing production adjustments.

• Switching to an indexable carbide milling solution delivered $97,000 in annual tooling cost savings while optimized cutting parameters reduced labor costs by an additional $50,000.
• The updated tooling approach minimized tool changes, reduced downtime, and shortened cycle times, improving overall manufacturing efficiency.
• Tooling upgrades combined with optimized speeds and feeds extended tool life and provided sustained value in the production process.