Value-added partner case study No. 12

The problem
A manufacturer of fire hydrants and water valves needed to increase productivity by 10 to 15 percent in a plant already operating round-the-clock shifts seven days a week. In one operation, long, stringy brass chips sometimes jammed collection augers and stopped production for about 10 minutes every 3.5 hours for workers to clear the stringers.

The solution
The manufacturer invited Sandvik Coromant to conduct a Productivity Improvement Program to review its current processes. The tool supplier recommended using Sandvik Coromant Grade 1025 inserts with high-feed wiper geometry to cut cycle times, extend tool life and enhance chip control.

The result
Using the new inserts, programmers increased feed from 0.0070 to 0.0120 in. per revolution. Surface cutting speed remained unchanged at 1,620 sfm. The result was a 71 percent reduction in cutting time, from 51.42 seconds to just 1.5 seconds. Overall cycle time including non-cutting time fell from more than 1 minute to just 24 seconds. In addition, tool life increased from 125 parts per edge to 400 parts per edge. Plus, smaller, more manageable chips eliminated shutdowns for cleaning. The cumulative effect of the cycle time reductions and increased tool life was a 153 percent increase in productivity for the OD turning operation.

The documentation
Click here to see how Sandvik Coromant summarized how its suggested tool and process changes could hike productivity by 17 percent, trim tool inventories 65 percent and save more than $466,000 a year.

The story
Click here to read about how Sandvik Coromant earned the 2002 Value-Added Partner of the Year Award from the Industrial Supply Manufacturers Association.