The key to cost savings is improving efficiencies at the spindle — and that’s the focus of Triumph Tool’s Documented Cost Savings initiative. If your machining process can be run more efficiently, then you can increase the productivity of your entire operation. As a result, you can drive a direct increase in profits for your organization by implementing changes in your Manufacturing processes.
For the team at Triumph Tool, the Documented Cost Savings initiative is one of the ways we go out of our way to build strong relationships with our customer partners. To learn more about this initiative, you can keep reading or contact us.
How Do We Do It?
At Triumph Tool, we target 10% of our sales to show documented cost savings for our customers. Our Documented Cost Savings program will identify potential factors for improved efficiency, such as the following:
- Reduced Cycle Time
- Longer Tool Life
- Decreased Tooling Cost Per Piece
- Process Changes, Combining Tools into Specials
- Elimination of Unnecessary Tools or Machines
- And Other Areas
Once the areas for improvement have been identified, successful testing completed and then documented, we will present them to you, review and get your approval. This provides us with a mechanism for transparency and the opportunity to further discuss other areas that mayshow improvements within your facility.
Want to see concrete examples of Documented Cost Savings? View our Case Studies below to learn how we have helped past customers.
Case Study #1:
In this first case study, our team was able to provide a solution for one of our largest customers, a production manufacturer of automotive components. Our local Sales Representative was tasked to find a solution in a current application that saved time and improved surface finish. The existing process was an indexable solution and consisted of three tools used for both rough and finish. The new tool process consisted of two tools, indexable to rough and a high-performance cermet reamer to finish. The details of the application follow:
- Cycle time: 225 seconds
- Tool life: 125 parts per indexing of the insert
- Cycle time: 35 seconds
- Tool life: 2500 parts per indexing of the insert
By removing a tool from the process, we were able to lower the customer’s cycle time by 190 seconds, giving them the ability to make more parts in an average business day. The new tool was also changed 80% less, which eliminated potential downtime, and the tolerance of the diameter and the surface finish was greatly improved, allowing the customer to make better quality parts.
The case study showed that using the new HP reamer process would lead to hard tooling savings of $63,000 as well as soft time savings of $323,000. Overall, the solution proposed by the case study offered the customer total savings of $386,000 per year. Our customer was extremely happy with the results and implemented them immediately. They are currently looking at other applications that can use similar technology.
Case Study #2:
In this second case, one of our customers — who manufactures components for the aerospace, nuclear and defense sector — was having issues with the amount of time manual deburring at a high cost. Our Sales Representative offered a solution with a unique ceramic technology that made a huge impact on their throughput.
The customer was using a material called WR®525, which is a thermoplastic composite consisting of carbon fiber with unique thermal expansion properties. This material is very hard on tooling and the client’s existing carbide tool only lasted 20 pieces. It was being used by 4 people working on 5000 parts per week at an average of 10 minutes per part.
With our new technology, using a ceramic deburring stick, the customer was able to increase the tool life to 250 pieces and lowered the average time per part to 5 minutes — half of the original time. The overall cost savings for this adaptation, which we documented and shared with our customer, is $124,000 per year.
Contact the team at Triumph Tool to learn more about our Documented Cost Savings. Let us help your business find solutions that save.