Custom Form Tool Eliminates a Milling Operation and Saves $280,000 Annually
Fullerton designed a custom form tool that allowed a customer to complete turning, milling, and shaping operations on a Swiss-style lathe. By eliminating the need for a separate milling center, the customer reduced cycle time from minutes to seconds and saved $280,000 annually.
At a Glance
The Challenge
The customer's process required two machines to complete a single part. The part was first turned and parted off on a Swiss-style lathe, then moved to a separate milling center, where multiple tools were used to complete the final shape.
Moving the part between machines added handling and cycle time. The process also tied up an entire milling center that could have been used for other production.
The customer needed a way to complete the part on the Swiss-style lathe without requiring a separate finishing operation.
The Solution
Fullerton designed a custom form tool that could run in the live tooling bed of the customer's Swiss-style lathe.
The custom tool allowed the turning, milling, and shaping operations to be completed in one setup before the part was cut off. This eliminated the need to move the part to a milling center and reduced the number of tools required to finish it.
Completing the entire process on one machine also reduced part handling and opened additional milling capacity for other work.
The Results
The custom form tool improved both production time and equipment utilization:
- The milling center was removed from the process: All required shaping could be completed on the Swiss-style lathe.
- Cycle time dropped from minutes to seconds: The customer eliminated the time required to move, set up, and machine the part on a second piece of equipment.
- Additional machining capacity became available: The milling center could be reassigned to other production.
- Annual costs decreased by $280,000: Shorter cycle times, less machine time, and additional production capacity delivered significant annual savings.
One machine. One setup. Minutes turned into seconds.
When Does This Approach Make Sense?
A custom form tool designed for live tooling may be worth evaluating when:
- A part requires both a Swiss-style lathe and a separate milling center
- Secondary machining operations are adding significant cycle time
- Moving parts between machines adds handling or setup requirements
- A milling center needs to be freed for other production
- The Swiss-style lathe has live tooling capabilities that could support additional operations
When a part can be completed in one setup, a custom form tool may reduce cycle time while making better use of available equipment.
Frequently Asked Questions
How much did the custom form tool save annually? +−
The custom form tool saved the customer $280,000 annually by eliminating the need for a separate milling center and reducing cycle time from minutes to seconds.
How did the custom tool eliminate the milling center operation? +−
Fullerton designed the form tool to run in the live tooling bed of the customer's Swiss-style lathe. This allowed the turning, milling, and shaping operations to be completed in one setup before the part was cut off.
How much did cycle time improve? +−
Cycle time was reduced from minutes to seconds by completing the operation on the Swiss-style lathe instead of moving the part to a second machine.
What machine platform was the custom tool designed for? +−
The custom form tool was designed to run in the live tooling bed of a Swiss-style lathe.
What additional benefit did the customer gain? +−
In addition to reducing cycle time, the customer freed an entire milling center for other production.
Running a Part Across Two Machines?
Tell us about your part and machine platform and our engineering team will see if it can be finished in one setup.
