http://blog.lenoxtools.com/industrial-metal-cutting/feed/

Industrial Metal Cutting Blog

Lenox Institute of Technology
About
Contact Us

cost per cut

Tips for Improving Circular Saw Blade Life in Ball and Roller Bearing Production

May 30, 2016 / , , , , , , , , , ,

For any metal-cutting operation, bottlenecks are the enemy. Whether caused by machine error, tooling failure, user error, or some other maintenance issue, the end result is typically the same—increased downtime, rework, and scrap, all of which eat into the bottom line. And for a high-production operation like ball and roller bearing manufacturing, a hiccup in early sawing operations can quickly wreak havoc on the entire production process and schedule.

Although circular sawing may seem like a simple operation, there are number of variables that play a role in achieving consistent, quality cuts while also getting the most out of each saw blade. As an archived article from Fabricating & Metalworking explains, “Saws are very much like the people who use them: they don’t react well to heat, shock, abrasion, stress, and tension.” Far too often, managers and operators ignore these critical factors and, as a result, experience premature blade failure and end up going through far more blades than necessary.

Proper cutting speeds, feed rates, blade tension, and lubrication all tie into blade life—a factor any blade buyer knows is critical when it comes to cost.

“Precision circular saw blades can be upwards of  $200 a piece, so you don’t want to just go through those,” Mike Baron, vice president of Jett Cutting, says in a case study published by the LENOX Institute of Technology (LIT). “If I am getting 100 pieces an hour at this setting, but push it up to get 150, I may be going through twice as many blades. It just isn’t cost effective.”

Glen Sliwa, maintenance manager at metal service center A.M. Castle & Co, also focuses on blade life to better manage costs. In addition to following a strict preventative maintenance program to save on tooling and equipment costs, Sliwa says it is just as critical to ensure operators know how to optimize blade life. This includes training operators to follow manufacturer suggested cutting parameters, as well as closely tracking tolerance requirements so blades can be reused whenever possible.

“We’re looking at how many pieces that we can get off that blade and then stand perpendicular to the part,” Sliwa explains. “If you have to stay within ten-thousandths or five-thousandths on the cut, and that blade is no good, I can take it off that machine and put it on another one and I can cut an eighth of an inch, 125 thousandths. So I’m still getting more blade life out of it, but it’s not interfering with that customer’s specifications.”

To help ball and roller bearing manufacturers extend the life of their circular saw blades, the below chart offers a few troubleshooting tips from LIT’s reference guide, “Tips and Tricks to Optimize Your Precision Circular Sawing Operation.” By understanding some common blade issues and their root causes, operators can reduce premature blade failure and, in turn, improve your  operation’s overall productivity and save on tooling costs.
chart 3

For more downloadable information on optimizing your company’s precision circular sawing operation, you can visit LIT’s resource page here.

cost per cut

Software Tools Help Fabricators Improve Productivity

May 10, 2016 / , , , , , , , , , ,

As fabricators continue to seek new ways to optimize their operations, many are turning to software. Whether using it to connect the plant floor to the front office, or to measure key performance indicators (KPIs), data shows that more and more fabricators view software as a smart—and necessary—manufacturing tool.

For example, according the “2016 Capital Spending Forecast” from the Fabricators & Manufacturers Association International, more than 94 percent of survey respondents said their software spending this year would either remain the same or increase. This is significant, especially as more and more reports show that many companies are pulling back on spending this year.

A separate benchmarking survey from Modern Machine Shop shows that leading shops are more likely to utilize advanced software programs in their operations. Specifically, the survey found that top-performing machine shops (referred to as “top shops”) are more apt to utilize software solutions like enterprise resource planning (ERP) and toolpath simulation software in comparison to other shops.

Valuable Solutions
While there are many reasons software is becoming a valuable tool for manufacturers, for fabricators, a lot of it has to do with evolving customer demands. “As more custom fabricators are taking on more design work—beyond just design for manufacturability—engineering and estimating functions become more complex, especially as that work focuses on more subassemblies and full assemblies that call for multilevel bills of material and a multitude of sourced parts,” states a report from thefabricator.com. This, the article continues, is causing shops to invest in better methods of communication, as well as software tools like CAD/CAM, nesting systems, and ERP.

The good news is that as more manufacturers embrace software, the more tools are being developed—both by software designers and supply chain partners. Like consumers, industrial manufacturers are finding that where there is a need or challenge, there is indeed “an app for that.”

In metal cutting, specifically, there are several tools fabricators can use to help optimize their operations—many of which are free of charge. Below are two in particular that fabricators may find helpful:

Enhance Your Toolbox
Having the right tool for the job has always been a critical part of any metal-cutting operation, but fabricators are finding that it pays to have more than just hardware in their strategic toolbox. While it will never replace the important work machinery and other hardware tools perform on the shop floor, software tools can further optimize cutting operations by measuring important metrics, analyzing job trends, automating certain functions, and educating operators on proper cutting parameters. Although some software programs can be costly in terms of both money and training time, there are plenty of free tools available that can help even the smallest fabrication shop improve their operations.

What software tools are helping your shop optimize operations?

cost per cut

Optimizing Your Metal Service Center with Cost per Cut Improvements

March 5, 2016 / , , , , , , , , ,

For any manufacturing company, cost reduction has always been—and will likely always be—a top priority. However, like many other business strategies, managers are starting to look at cost management holistically. Instead of simply looking at price tags and cost reduction, today’s managers are looking at long-term return on investment and optimization.

This type of “holistic” approach to cost management is being adopted by several large manufacturers, including food giant General Mills, but it can also be applied on the shop floor of any industrial metal-cutting operation. One specific way metal service centers can apply this concept is by measuring “cost per cut.”

Instead of simply looking at the cost of a blade or even how many cuts a blade performs,  “cost per cut” measures the total cost it takes for a shop to perform a cut, including raw material, blade, machine and operator costs. This metric gives service centers a better indication of overall production profitability.

A good analysis of cost per cut should include the following:

Of course, the question for many companies is not how to measure cost per cut, but rather, how they can reduce their cost per cut. Tools like the spreadsheet calculator, “ROI Analysis of Making Improvements to Cost Per Cut,” can be helpful in making that determination. The tool takes into consideration all equipment and factors beyond mechanics that can improve cost per cut rates and a shop’s bottom line.

Another optimization tool, SAWCALC, may also be helpful. The free, web-based software program recommends the correct band saw blade and sawing parameters based on material composition, size, shape and machine model, feed speed, as well as blade and tooth specifications that can streamline sawing processes and extend blade life.

One practical way service centers can reduce cost per cut is to consider investing in a coated saw blade. According to an article from Canadian Industrial Machinery, coating can extend blade life by 100 percent or more and slice cutting time in half, depending on the blade material, coating, and the material being cut.

Although coatings can add a premium of 30 to 50 percent to the cost of a blade, there are instances when the upfront cost can pay off. “You need a reason like a challenging material, a need for extra performance, or a machine that is creating a bottleneck and needs to produce more parts,” Daniel Fernandes, brand manager for band saw blades at LENOX, explains in the CIM article. “Upgrade to a coated blade and you can pump more jobs through the same equipment. You’ll get more out of your overhead costs and your labor.”

Another service center, featured here in a case study, was able to improve its cost per cut by re-adjusting its sawing parameters, increasing its operator training, and upgrading some of its blades. In one instance, the service center was able to reduce cut time by 40 percent.

Is a new, upgraded blade always the answer? Of course not, but optimization should always be the goal. This is why metrics like cost per cut are so important. By focusing more on reducing the true cost of each cut—and not just the price tag of a blade—managers can optimize their metal-cutting operations and, hopefully, see the results in the bottom line.

How has your service center improved cost per cut? What tools have helped you optimize your operations?

cost per cut

Tips for Preventing Premature Band Saw Blade Failure in Your Forging Operation

January 25, 2016 / , , , , , , , , , , ,

For any metal-cutting operation, blade life is critical. Premature blade failure not only results in increased tooling costs, it can also increase downtime, rework, and scrap—all of which eat into the bottom line.

For forges that cut and process metal, however, blade life is even more crucial. The scale that forms on forged metal pieces can quickly deteriorate blade life, which makes blade selection extremely important. In most cases, forges require aggressive bandsaw blades with varied tooth geometries that can get underneath any scale buildup (i.e., carbide-tipped blades).

While choosing the right blade is a good start, blade life also relies on a variety of other variables, including proper cutting speeds, feed rates, blade tension, lubrication, and break-in procedures. As an article form Fabricating & Metalworking explains, “Saws are very much like the people who use them: they don’t react well to heat, shock, abrasion, stress, and tension.” Far too often, managers and operators ignore these critical factors and, as a result, experience premature blade failure and end up going through far more blades than necessary.

To help forges extend the life of their band saw blades, below are a few troubleshooting tips from the reference guide, “User Error or Machine Error?”, from the LENOX Institute of Technology. By understanding some common blade issues and their root causes, operators can reduce and, hopefully, eliminate premature blade failure.

Issue #1: Heavy Even Wear On Tips and Corners Of Teeth
The wear on teeth is smooth across the tips and the corners of set teeth have become rounded.

Probable Cause:

Issue #2: Wear On Both Sides Of Teeth
The side of teeth on both sides of band have heavy wear markings.

Probable Cause:

Issue #3: Wear On One Side Of Teeth
Only one side of teeth has heavy wear markings.

Probable Cause:

Issue #4: Chipped Or Broken Teeth
A scattered type of tooth breakage on tips and corners of the teeth.

Probable Cause:

Issue #5: Body Breakage Or Cracks From Back Edge
The fracture originates from the back edge of band. The origin of the fracture is indicated by a flat area on the fracture surface.

Probable Cause:

For more information on extending blade life, download the full reference guide, “User Error or Machine Error?” here, or check out The LENOX Guide to Band Sawing.

cost per cut

Benefits of Choosing Carbide Blade Technology for Your Metal Service Center

December 5, 2015 / , , , , , ,

Any metal-cutting expert knows that having the right blade for the job is critical. Although it may seem like a small operational detail, blade performance impacts several key business areas, including productivity, maintenance, quality, and tooling costs.

Like any purchasing decision, blade selection needs to be strategic, taking into consideration a host of variables—business goals, material type, equipment, and operator skill level, to name just a few. Blade performance is also based on several variables—the cutting application, blade specification, number of teeth per inch, tooth set, etc. Put simply, not every blade is created equal, and choosing the wrong blade can result in poor quality cutting and higher operational costs.

The problem is that many of today’s service centers don’t even realize they are using the “wrong” blade. In many cases, companies settle for “good” instead of “great.” Managers and operators become content with the blade technology they’ve been using for years and end up missing out on the benefits a new blade technology could bring to their operation.

This is a common occurrence in band sawing. For example, many service centers have used bi-metal band saw blades over the years and have had decent results. And in many cases, bi-metal blades are a good choice. However, there are applications in which carbide blade technology would be the better choice.

Many companies are finding that making the switch to carbide blade technology can provide savings and productivity gains they would never have achieved with bi-metal blades. This was the case for Aerodyne Alloys, a metal service center featured here in Today’s Energy Solutions. For years, the company’s Greenville, South Carolina facility used bi-metal blades to cut its toughest metals, including stainless steel, nickel alloy, and super-alloys like Inconel 718 and Hastelloy.

To gain more performance out of its band saws, Aerodyne decided to upgrade to carbide blades. Carbide-tipped band saw blades use strong, durable materials to provide high performance, faster cutting, and prolonged blade life. The blade tooth has carbide tips welded to a high-strength alloy backing, allowing the metal service center to take on hard, nickel-based alloys, as well as stainless steel, tool steel, and titanium.

In addition to tackling hard-to-cut metals, carbide-tipped band saw blades offer longer blade life and faster cutting. The white paper, Characteristics of a Carbide-Friendly Band Saw Machine, further elaborates the benefits of the carbide technology by providing a real-life comparison between a bi-metal blade and a carbide-tipped blade. The test produced the following results:

Ultimately, the higher speed and feed rate of the carbide blade enabled it to make the cut 13 minutes faster, translating into 160 more parts produced during an 8-hour shift than its bi-metal counterpart.

Carbide-tipped band saw blades can also deliver benefits to a metalworking operation by producing an improved surface finish. In many cases, a cut part will require additional processing steps downstream in order to refine the finish. By having a smoother finish, the carbide blade can reduce the number of secondary processes, which saves both time and money.

A good example of this is LENOX’s new carbide blade technology, which was featured in the latest issue of Modern Metals. Developed to cut aluminum and nonferrous alloys, the carbide-tipped band saw blade is able to make straight cuts at high speeds without sacrificing surface finish. As stated in the article, the blade tip’s particular grade of carbide wears very slowly, which is ideal for cutting aluminum. A multi-chip tooth pattern balances the chip load and reduces cutting forces, and sharp-edged teeth and high rake angles penetrate material more easily. The cutting tool is said to be the latest blade designed specifically to cut aluminum and nonferrous parts often used in today’s aerospace and automotive applications.

As carbide blade technology continues to advance, the more options service centers have to optimize and grow their operations. Whether the goal is to take on a harder material, improve performance, or increase quality, carbide-tipped blades are an investment worth considering. While the upfront product cost may be higher than other blade types, benefits like improved productivity, lower operational costs, and higher customer satisfaction will pay off in the long run.

For more information on the benefits of carbide blade technology, click here to download the white paper, “Leveraging Carbide Blade Technology to Increase the Productivity of Your Sawing Operation.”

cost per cut

Solving the Six Common Cutting Challenges Ball and Roller Bearing Manufacturers Face

August 30, 2015 / , , , , , , , , , , ,

Like most high-production operations, ball and roller bearing manufacturers are running on tight schedules and can’t afford unexpected downtime or tooling issues. This means that every step of the manufacturing process must be optimized, starting with the first operation—circular sawing.

While precision circular sawing may seem like a simple operation, any metal-cutting expert can confirm that proper cutting depends on several variables. As this article from Canadian Metalworking points out, the overall performance of your cutting tool depends on speed, feed, depth of cut, and the material being cut. Knowing how to balance these variables is critical to cutting success.

For example, according to the white paper, The Top Five Operating Challenges Ball and Roller Bearing Manufacturers Face in Industrial Metal-Cutting, increasing the speed of a saw to get more cuts per minute without considering the feed setting or the demands of the material will result in premature blade failure and increased tooling costs. This, in turn, can lead to unplanned downtime for blade change-out, which directly impacts productivity.

Understanding how these different variables affect the cutting process can also help operators quickly and properly resolve any cutting challenges that arise. In many cases, this knowledge can make or break a production schedule.

To help ball and roller bearing manufacturers keep their circular sawing operations running at optimal levels, the LENOX Institute of Technology offers the followings tips for solving six of the most common problems operators may face:

Problem #1: Excessive vibration or noise
Potential solutions:

Problem #2: Crooked cutting
Potential Solutions:

Problem #3: Wavy cutting
Potential Solution:

Problem #4: Chips are too hot or glowing
Potential Solutions:

Problem #5: Poor finish/Excessive stripping
Potential Solutions:

Problem #6: Heavy burr
Potential Solutions:

For more information on optimizing your precision circular sawing operation, including best practices, white papers, and case studies, check out LIT’s resource center here.

cost per cut

Guidelines for Cutting Structural Tube in Your Fabrication Shop

August 10, 2015 / , , , , , , , ,

As reported in our recent Metal-Cutting Industry Report on Non-Residential Construction, the use of industrial and structural steel tube and pipe is growing. According to a market tracker from Metal Bulletin Research (MBR), the category is growing at the fastest rate since the recession, mostly due to economic growth and falling oil prices.

“Construction demand for structural tubing is now growing at a steady pace in most regions of the USA,” the MBR report states. “There has been some concern among market participants that the drop in oil prices and the associated hit to the local energy-centered economies would be detrimental to their construction outlook, especially since these were some of the initial drivers of growth in the recovery. So far, construction continues unabated, as contracts, financing and permitting have already been settled.”

Industry players are also optimistic. HGG, a supplier of tube-processing machinery, told MetalForming magazine it expects the category to grow by about 15 percent in North America alone. (You can read the full MetalForming article here.)

This is good news for fabricators that serve the industrial and commercial construction industries or that cut structural tube for other applications. In either case, most shops are working with hollow structural steel (HSS) tube specified to ASTM A500 (the standard specification for cold-formed welded and seamless carbon steel structural tubing in round, square and rectangular shapes). Although most shops wouldn’t categorize HSS as difficult to cut, it does have some unique characteristics operators need to understand to ensure proper cutting.

Unlike solid tubing, which only requires one cut, HSS tube requires the blade to cut through two thin solids with a space in between. These types of cuts—known as interrupted cuts—are best suited for bi-metal band saw blades because they are designed to withstand the vibration. Carbide band saw blades, on the other hand, have strong, durable teeth, but they are not shock resistant. Therefore, bi-metal blades that reduce harmonics are the best choice.

HSS tubes also aren’t ideal for bundle cutting. While cutting tubing in bundles can allow shops to increase the number of parts per shift, it can substantially reduce blade life. In fact, some experts say that any increased part volume efficiency is offset by a 20 to 25 percent reduction in band life.

A recent article from thefabricator.com highlights several other best practices for sawing structural tube. The following are a few of the industry publication’s tips:

For more guidelines on cutting HSS tube, including a discussion on circular saw blade options, you can read the full thefabricator.com article here.

cost per cut

Tips for Cutting Superalloys in Your Metal Service Center

August 5, 2015 / , , , , , , , , ,

Over the next few years, experts anticipate growth in the use of high performance alloys or “superalloy” materials such as Inconel and Hastelloy. The high-performance metals, which are known for their outstanding corrosion and high temperature resistance, continue to find uses in aerospace and aircraft applications, and more recently, are expanding into the oil and gas industries.

“Growing corrosion as a cost concern in exploration and production in offshore drilling rigs is expected to propel use of high performance alloys such as superalloys in oil and gas applications,” states one study from Grand View Research, Inc. “Non-ferrous alloys such as nickel and titanium are also expected to witness above average growth due to their high mechanical strength coupled with increased use in aerospace, oil & gas and gas turbine applications,” the study continues. Specifically, Grand View Research forecasts that superalloy demand will experience an annual compound growth rate of more than 3.0 percent from 2014 to 2020.

While there is certainly a science to cutting any metal material, tackling tough-to-cut materials like superalloys can be even more challenging as managers try to balance cutting speed, finish quality, and blade life. However, with the right tools and know-how, service centers can efficiently and cost-effectively handle tough-to-cut materials without compromising quality.

The following are three key tips for service centers that want to cut superalloy materials:

cost per cut

Five Tips for Using Metal Cutting Coolants in Ball and Roller Bearing Production

July 30, 2015 / , , , , , , , ,

As any machining expert will tell you, coolants are a critical part of the metal-cutting process. While they are an added cost and an added step in the production process, the long-term cost benefits of coolants are worth every dime and every minute spent. This is especially true if your goal is optimization. As an article from Production Machining states, manufacturers should view coolants as an asset or, better yet, a “liquid tool.”

Unfortunately, many managers and operators fail to understand the importance of  proper lubrication during the metal-cutting process. According to Modern Machine Shop, most manufacturers see lubricant as “the least important factor in the total cost of machining and the last place to look for process improvements.” In fact, it is common for companies to often “cheat” on the proper concentration levels of metal-cutting fluids in order to save money. This may reduce coolant costs in the short term, but the high costs of machine wear and tooling replacement make this a poor management choice.

As explained in the white paper, Understanding the Cut: Factors that Affect the Cost of Cutting, coolants provide lubrication, which is essential for long blade life and economical cutting. Properly applied to the shear zone, lubricant substantially reduces heat and produces good chip flow up the face of the tooth. Without lubrication, excessive friction can produce heat; high enough to weld the chip to the tooth. This slows down the cutting action, requires more energy to shear the material, and can cause tooth chipping or stripping, which can destroy the blade.

Like any manufacturing tool, proper use and coolant management is essential if you want to get the most out of your investment. To help ball and roller bearing manufacturers ensure proper lubrication management in their metal-cutting operations, the LENOX Institute of Technology offers the following five tips:

  1. Start with a clean machine. As an article from MoldMaking Technology explains, proper metalworking fluid management starts with the draining, cleaning, and recharging of the machine. When changing coolants for any reason, clean and disinfect thoroughly with a fluid advised by the supplier of the coolant.
  2. A proper fluid mix is key. Extending the life of your fluids and achieving the best fluid performance starts with proper fluid preparation. Metal-cutting fluids need to be mixed a certain way in order for their chemical makeup to be correct. Experts recommend pouring the water into the mixing container first and then stirring the coolant concentrate into the water. One way to remember the proper technique is by the acronym O.I.L. (Oil In Last).
  3. Remove tramp oil to extend fluid life. Waste oils, which come from the machine or surfaces of the raw materials, are often picked up by the metalworking fluid and are referred to as “tramp oils.” Regular removal of tramp oil from the manufacturing process helps improve fluid performance and longevity, air quality, bacterial resistance, corrosion resistance, and tool life. Typical methods for tramp oil removal include regular inspection and the use of skimmers, centrifuges, and coalescers.
  4. Monitor fluids regularly. Measure, with a regular frequency, the concentration and quality of your fluids. Testing tools include refractometers, which can quickly determine the total amount of solubles in a solution, or titration kits, which are more extensive and are used to analyze fluid concentration in metal-cutting fluids contaminated with tramp oils. Tests for PH levels and alkalinity can also be useful,  as pH readings outside the acceptable range indicate a need for machine cleaning, concentration adjustment, or the addition of biocide.
  5. Make coolant checks part of everyday maintenance. Instituting regular coolant checks as part of a preventative maintenance program or daily operator checks can eliminate unnecessary tooling costs and maintenance downtime. Low coolant levels on a band saw, for example, can lead to premature and uneven wear of band wheels, which typically cost $1,000 each.

While coolants may feel like just another cost item on your consumables list, they play an important role in keeping maintenance costs down and cutting tool performance high. By following a few best practices, ball and roller bearing manufacturers can ensure that their metal-cutting coolants are not a necessary evil, but an opportunity to improve process efficiencies.

cost per cut

How Fabricators Can Benefit from Tooling Investments

July 10, 2015 / , , , , , , , ,

Most operations managers understand the importance of keeping productivity high and costs low. However, many managers fail to understand that in many cases, spending more in the short term is necessary to achieve the long-term goal of productivity.

This concept is especially true when it comes to metal-cutting tools. Because tools are consumables that need to be purchased and replaced often, it is tempting for managers to focus more on upfront cost. But as the following examples will explain, this strategy does not always offer the best return on investment.

Productivity Pays
At an event held earlier this year, Jacob Harpaz, CEO of Ingersoll Cutting Tools, explained why managers need to look beyond the price tag when investing in a new tool. According to Harpaz, featured here in Modern Machine Shop, a cutting tool can deliver improvement in three ways:

  1. Lower price
  2. Longer tool life
  3. Greater productivity

Although all three can be beneficial, Harpaz says choosing a tool with greater productivity will always offer the most lucrative return. Here’s why: For a representative machined part, Harpaz estimates that the cost of machinery represents 26 percent of the cost of machining a part; overhead represents 21 percent of the unit cost of machining; and  labor and raw material account for 28 and 22 percent, respectively. Meanwhile, the cost of cutting tools accounts for just 3 percent.

The implications of this are significant, according to Harpaz. Using the above estimates, dropping the price of the tool by 20 percent would only deliver a 0.6-percent unit cost reduction. The seemingly even greater change of increasing the life of the tool by a factor of 2 would still only save 1.5 percent. However, increasing productivity would increase the number of pieces the shop can produce in the same period of time, which means the labor cost, overhead cost, and machinery cost per piece would all decrease. Increasing productivity by 20 percent, thus, produces a savings of 15 percent overall, providing the greatest savings opportunity.

Benefits of Upgrading
With the above in mind, managers that want to get the best return out of their tooling need to remain open about investing in upgrades and new technologies In saw blades, advancements in tooth geometry and wear-resistant materials are providing significant improvements for many metal-cutting operations. This article from Canadian Industrial Machinery, for example, explains why the additional cost of a coating on a band saw or circular saw blade can be worth the investment, especially when cutting a challenging material or when higher performance is needed.

There is no question that high-performance blades will cost more. However, because they are able to cut faster and with more accuracy, they improve productivity and save money in the long run. O’Neal Steel, a Birmingham, Alabama-based fabricator featured in a white paper from the LENOX Institute of Technology, found that incurring a significant upfront expense to upgrade some of its blade was worth it. Before the upgrade, O’Neal was spending about $90 per blade, but the fabricator was only getting one day’s worth of cutting. “We had a fair margin, but we were constantly messing up material,” explains Jim Davis, corporate operations services manager. “Most people think it’s costing a lot of money in blades to switch. Well, that’s true, but when you’re cutting really tight tolerances, your blade’s going bad and the material lengths are off, you can add up money really fast and lose all your profits in just an hour or two if you have blade issues.”

For another job in its Knoxville, TN, location, O’Neal was only getting two days of cutting per blade, so they were going through three blades a week. Again, Davis upgraded from a blade costing $280 to one that was $40 more, and immediately his blade-life increased to seven days.. He estimates that in the long run O’Neal saved $600 a week, or an annual total of around $30,000. “That’s a radical change, about a 3:1 ratio on the life of a blade,” said Davis.

The Deciding Factors
Of course, not every upgrade will be worth the cost. The key is for managers to weigh the opportunity cost against the hard cost, considering the true benefits a new tool can offer and whether or not it will contribute positively to the bottom line. To do this effectively, managers need to work closely with their tooling partners to discuss the pros and cons of the different metal-cutting options, while also evaluating all of the factors that contribute to the cost of the cutting process. If the long-term benefit is there, managers need to be sure they aren’t being shortsighted by the price tag. As fabricators like O’Neal are finding, the upfront investment may offer higher productivity, as well as substantial bottom-line savings.

1 2 3