Product category:
Tool management systems
News Release from: WNT (UK) | Subject: Tool vending system
Edited by the Manufacturingtalk Editorial
Team on 02 May 2005
Tool vending scheme saves GBP 20,000
Employing a tool supplier to manage tooling in the form of tool vending has generated immediate savings estimated at GBP 20 000 by releasing manpower to other areas of the business.
Arundel-based subcontractor IEC Engineering has created a business of two halves, with one machine shop specialising in medium to high volumes of general engineering components and a second concentrating solely on low volume components for the aerospace industry The resulting 70 employee, GBP 6 million turnover business therefore has a requirement for an extensive range of cutting tools that demands careful stock control and management
This article was originally published on Manufacturingtalk on 21 Apr 2008 at 8.00am (UK)
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This responsibility falls on the shoulders of Jon Keen and Simon Lawrence, Divisional Managers of the respective aerospace and commercial divisions.
IEC had previously relied on the support of a local tool distributor accessing a wide range of products from various manufacturers.
However, as IEC's business developed, particularly in the aerospace sector, it became apparent that the existing supplier could not provide the in-depth technical support and related cost savings that were required.
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The search for an alternative began at MACH 2002 and it was there that the current partnership with WNT (UK) began.
Initially WNT focused on IEC's drilling requirement and a successful outcome led to both companies working together on IEC's rotary cutting tool requirement.
The first stage saw WNT charged with reducing tooling costs through a mixture of inventory control and process improvements.
Within the first year savings of 21% on 'like-for-like' tooling were achieved, and in the second year the emphasis shifted to process improvement, with regular site visits by Lee Pinhorne, WNT's technical sales engineer.
By year three the relationship had become one of ongoing improvements and total tool management support.
One aspect of this support has been the installation of tool vending in the commercial division.
This generated immediate savings estimated at £20 000 by releasing manpower normally associated with tool management to other areas of the business.
Although there was some initial concern that tooling costs could get out of control without manual intervention, like for like tooling costs actually fell following the installation of the first vending unit.
The commercial division has two vending machines installed at no cost to IEC.
These units control over 90% of the division's tooling requirements, with orders processed automatically on a weekly basis.
At the same time as the order is issued a detailed report is provided to IEC.
This highlights tool usage by spend and has the double benefit of allowing IEC to monitor tool use by operators while contributing to cost control on individual component manufacture.
This reporting routine also creates a rolling report detailing the top ten tooling items by spend.
IEC then works with WNT on how best to cut the costs relating to these items.
"Tool vending has now superseded our consignment stock system and the immediate benefit is accountability," says Lawrence.
"Every operator has an individual 'key' to vend and we know who is using what, and on what jobs".
"So Lee Pinhorne is now free to fine tune our processes by testing different inserts and grades." This fine tuning, particularly in the commercial division, where volumes are substantially higher, has made a significant difference to tooling and production costs.
For example, to mill a profile on a mild steel bracket WNT suggested using one of its 50 627 160 solid carbide end mills.
Although this particular cutter is 37% more expensive than the existing cutter, tool life has increased by 84% and cycle time has reduced by 61%.
As a result annual tooling costs on this component have reduced by almost GBP 400 accompanied by a GBP 2,043 saving in machine time.
The support and service provide by WNT is acknowledged by Keen.
"Prior to installing the vending machines our spend on tooling equated to 5% of turnover".
"This figure has now reduced to 2% in the commercial division and 3.5% in the aerospace division." In the case of the aerospace division, it is now expected to follow the example of the commercial division and install tool vending. Request a free brochure from WNT (UK) ...
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