Custom Saw Redesign Doubles Tool Life and Saves $177,000 Annually
When saw usage started climbing and arbor failures kept interrupting production, an automotive manufacturer needed more than another replacement tool. They needed to fix the problem behind it.
Fullerton redesigned the saw profile, updated the regrinding process, and expedited the project. The result? Twice the tool life, no more unplanned failures, and $177,000 in annual savings.
At a Glance
The Challenge
An automotive manufacturer was experiencing ongoing performance problems with its existing saw tooling. Tool usage was climbing, performance was inconsistent, and recurring arbor failures were causing unplanned downtime.
The tooling simply wasn't holding up to the demands of the application — and continuing to replace it wasn't solving the real problem. Every failure meant another interruption, another replacement, and another hit to production.
The Solution
Fullerton's sales and engineering teams worked together to quickly identify and address the problem. Because the customer was dealing with an active production issue, the redesign and order were expedited. The team:
- Developed changes to the saw's profile
- Updated the regrinding process for the tool
- Produced an experimental design for testing
- Used the results to refine the final tool
The experimental saw profile outperformed the original design and ultimately became the foundation for a new, more cost-effective standard tool.
What began as an urgent production problem turned into a better long-term tooling solution.
The Results
The redesigned saw delivered improvements where they mattered most:
- Tool life doubled: The customer could run twice as long before replacing the saw.
- Unplanned failures were eliminated: The recurring arbor failures and inconsistent performance stopped with the new design.
- Annual costs dropped by $177,000: Longer tool life and less downtime delivered significant savings across the operation.
Fewer replacements. Fewer surprises. And a much healthier tooling budget.
When Does a Custom Saw Redesign Make Sense?
A custom saw redesign may be worth considering when:
- Standard saw tooling is wearing or failing faster than expected
- Tool usage continues to increase without a clear explanation
- Performance varies from one tool to the next
- Existing tooling is damaging arbors or other equipment
- Tool failures are creating costly production interruptions
- The application needs quick engineering support to keep production moving
If you're replacing the same tool — and dealing with the same problem — over and over, it may be time to look at the tool design instead of ordering another one.
Frequently Asked Questions
How much did the custom saw redesign save annually? +−
The redesigned saw saved the automotive manufacturer $177,000 annually. The savings came from doubled tool life and the elimination of unplanned tool failures and related downtime.
How much did tool life improve? +−
Tool life doubled compared to the saw tooling used before the redesign. This significantly reduced how often the customer needed to replace the tool.
What problems led to the custom saw redesign? +−
The customer was experiencing inconsistent saw performance, increasing tool usage, and recurring arbor failures. These issues were increasing both tooling costs and production downtime.
How quickly did Fullerton respond? +−
Fullerton treated the project as an expedited order. Sales and engineering worked together to quickly develop, test, and implement the necessary design changes.
What industry was the custom saw designed for? +−
The custom saw was developed for an automotive manufacturing application.
Replacing the Same Tool Over and Over?
Tell us about the problem behind it and our engineering team will help you redesign the fix.
