Perry, Oklahoma COST SAVINGS BREAKDOWN October 2019 – March 2020 Machine: Workpiece: Material: Ten. Strength/hardness: Operation: TOTAL Cost Savings: Machine: Workpiece: Material: Ten. Strength/hardness: Operation: TOTAL Cost Savings: Machine: Workpiece: Material: Ten. Strength/hardness: Operation: TOTAL Cost Savings: TURNING Mori-Seiki CL-200 BALL VALVE SAE 52100-GCr15-High Chrome 50 HRC Finishing $142,966.67 Hardinge Valve SAE 52100-GCr15-High Chrome 50 HRC Rough Turning $84,078 Mor-Seiki SL-2 Hub Cast Iron Roughing $9,689.33 E-Z Drill benefited from switching to different inserts and finding the correct CBN grade and chip breaker. The improvement? With Fastenal, E-Z Drill was able to make 50 pieces per edge compared with the previous 20 pieces per edge. Working with E-Z Drill’s team, Fastenal helped identify that an incorrect chip breaker and grade were being used. When the correct insert was plugged in, they went from 5 parts per edge to 50 parts per edge. By making sure the correct chip breaker and grade were being used, Fastenal helped E-Z Drill reach 300 parts made per insert, a 200 part increase. Machine: Workpiece: Material: Ten. Strength/hardness: Operation: TOTAL Cost Savings: Machine: Workpiece: Material: Ten. Strength/hardness: Operation: TOTAL Cost Savings: HAAS/VF40 Adapter Plate 1018 Flame Cut Drilling $8,751.42 HAAS/VF40 Adapter Plate 1018 Flame Cut Drilling $3,077.52 DRILLING Replacing old technology reduced a bottleneck in the process where drilling was the longest time consumer. Cycle time went from over 3 minutes to 25 seconds. Again, replaced technology to reduce drilling time from almost 2 minutes per hole down to 10 seconds. Machine: Workpiece: Material: Ten. Strength/hardness: Operation: TOTAL Cost Savings: HAAS/VF40 Adapter Plate 1018 Flame Cut MILLING Circ. Interpolate holes 1.0516 & .9375 $3,030.97 On the drilling application, E-Z Drill was having a hard time holding tolerance with the drills they were using. So, as a secondary operation, they had to come in with a mill and cut the holes to size. Fastenal recommended drills that not only completed the holes quicker but also held size. This allowed for the elimination of the milling cycle altogether. TOTAL COST SAVINGS: $251,593.91 WF_128225_Written Case Study_E-Z Drill_6.20 JP To reach out to a Metalworking Lead, please email metalworkingleads@fastenal.com.
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