One Custom Tool. Three Operations.
$114,729 in Annual Savings.
Sometimes the biggest cost savings come from taking a few tools out of the equation. By combining drilling, chamfering, and back-chamfering into one custom tool, Fullerton helped a high-volume manufacturer reduce tooling costs, eliminate more than 1,000 tool changes, and save $114,729 annually.
At a Glance
The Challenge
A high-volume manufacturer was using three separate tools to complete one operation: one for drilling, one for chamfering, and one for back-chamfering. That meant three tools to purchase, manage, and replace — and multiple tool changes for every part.
Over the course of a year, the process required 361 tools and added significant machine downtime. Those extra tool changes may not seem like much one at a time, but when they happen more than 1,000 times a year, the cost adds up quickly.
The Solution
Fullerton's engineering team designed a single custom tool that could handle all three operations:
- Drilling
- Chamfering
- Back-chamfering
Combining the operations into one tool eliminated the need to move between three separate tools. The manufacturer reduced its tooling inventory, freed up space in the tool magazine, and kept the machine cutting instead of waiting through another tool change.
One tool. Three operations. A whole lot less stopping and starting.
The Results
The custom Drill/Chamfer/Back-Chamfer tool delivered significant savings across the entire operation:
- 267 fewer tools per year: Annual tool usage dropped from 361 tools to just 94 combination tools.
- 1,068 fewer tool changes: Eliminating those changes saved more than $10,500 annually in changeover time and related costs.
- $114,729 in total annual savings: The manufacturer reduced both its tooling spend and the downtime associated with changing tools.
The result was a simpler, more efficient process — and fewer tools standing between the machine and the next finished part.
Watch It in Action
See how the custom Drill/Chamfer/Back-Chamfer tool completes all three operations in a single setup.
When Does a Combination Tool Make Sense?
A custom Drill/Chamfer/Back-Chamfer tool may be worth evaluating when your application involves:
- Drilling and chamfering both sides of a hole
- Repeating the same multi-step operation in high-volume production
- Frequent tool changes that add cycle time and machine downtime
- Limited space in the machine's tool magazine
- Multiple tools that could potentially be combined into one operation
If three tools are performing one repeatable job, there may be a better way to make chips.
Frequently Asked Questions
How much did this custom tool save annually? +−
The custom Drill/Chamfer/Back-Chamfer tool delivered $114,729 in annual savings. It reduced annual tool usage from 361 tools to 94 and eliminated 1,068 tool changes.
What operations does the custom tool combine? +−
The tool combines drilling, chamfering, and back-chamfering into one custom tool body. These operations previously required three separate tools.
Why does reducing tool changes save money? +−
Every tool change adds machine downtime and creates another opportunity for setup error. Eliminating 1,068 annual tool changes saved more than $10,500 in changeover-related costs alone — not including the additional savings from purchasing fewer tools.
Is this type of custom tool suitable for high-volume manufacturing? +−
Yes. Combination tools can make a significant impact in high-volume applications where the same multi-step operation is repeated throughout the year. The more frequently the operation runs, the faster those time and tooling savings add up.
Think Three Tools Could Become One?
Tell us about your application and our engineering team will help you find out.
