This job was originally run in 3 operations using two vises in a vertical machining center. The total setup time for each operation averaged 30 mins. The parts were machined 4 at a time and changed out by an operator at the end of the cycle.

The following reorder, the company used the Pallet Retention System. All 3 operations were combined onto a single paIIet so each cycle yielded 6 finished parts instead of 4 parts still requiring 2 more machining operations. Setup time was cut from 90 mins to 20 mins and the time the machine sat without running (spindle idle time) decreased from 35 seconds to 15 seconds per cycle. This translated to the individual part change time dropping from 26.25 sec per part (25sec ÷ 4 parts x 3 ops = 18.75sec) to only 2.5 seconds! (15sec ÷ 6 parts x 1 op = 2.5sec)

The Bottom Line: Parts per cycle went from 4 unfinished parts (requiring 2 more operations) to 6 completely finished parts. Spindle idle time was cut by a whopping 90% and overall production was boosted by 53%. This job proved that significant savings can even be made on smaller quantity orders.

Projecting the job wouldn't be finished before the tight due date, the foreman quickly designed and cut a fixture from a blank PRS 6x12 paIIet. Parts were held 4 per pallet using Pitbull clamps. Setup time increased to an average of 60 mins per operation due to the extra time needed to create the fixtures, however what used to take 20 seconds to swap out a single part was now taking 15 seconds to change the entire pallet of 4 parts; a new average of 3.75 seconds per part. This average part-change time was cut down by 81%.

The Bottom Line: Spindle idle time was reduced by 81%. Overall production was boosted 27%. This job has repeated 5 more times to date saving the company $3,546!

Our customer was originally using a fixture plate and then holding one part at a time in a standard vise. The part's thickness and flatness was critical. They were having problems holding tolerances due to small chips left on the fixture plate. Also, they were using 6 screws to hold the parts which made part changes extremely slow.

We introduced them to our Pallet Retention System and designed a custom fixture plate to piggyback on one of our paIIets. They were now cutting 2 parts per cycle and, to their foreman's delight, had NO SCRAPPED PARTS because the operator had time to thoroughly clean the fixtures. What originally took about 5 days to complete, they were shipping in 3. They realized a 47% increase in output on the first job.

The Bottom Line: Part per cycle doubled. Spindle idle time decreased by 91%. Overall production was boosted by 47%. Best of all, this job has repeated 5 more times to date saving the company $10,704.

In a previous production run, our customer set up four 6" vises across the table of their Haas Toolroom mill. They were completing 8 parts every 30 minutes.

Upon installing a Pallet Retention System they were able to hold 18 parts on a single 6x12" PreEngineered EZ Pallets. They were now cutting 18 parts every 54 minutes.

The Bottom Line: Spindle idle time decreased by 94%. Parts per cycle more than doubled from 8 to 18. They saved $853 on one operation alone, not to mention they would have needed 9 vises to hold this many parts. The math: 9 Vises x $450 per vise = $4,050!

Previous to purchasing a vertical machining center our customer, Chariot Carriers Inc, was using small vises to hold parts individually as an operator drilled holes with a drill press. They were completing 2 parts per minute.

Upon installing a Pallet Retention System in their new VMC they were able to hold 24 parts on a custom designed 6x16" paIIet using Uniforce Clamps. They were now drilling 24 parts every 2 minutes 30 seconds.

The Bottom Line: Spindle idle time was only 15 seconds to change out a pallet of 24 parts. They improved production by a whopping 200% and saved $2091 on the first job alone!