Case Study in High-Volume Machining: Fast Turnaround on a New Aerospace Part
At Tool Technology, we’re built to handle high-volume machining. But scale isn’t our only strength.
Many shops can deliver quantity, or tight tolerances, or quick-turn manufacturing, but few can deliver all three at once. We recently took on a demanding project that showed our ability to combine all of these for a single customer, helping a customer hit aggressive timelines even on a complex part.
The Challenge: Complexity at Scale on a New Part
An aerospace customer needed a new part from us, and they needed it quickly. We’re well-versed in the industry, with a long history of aerospace manufacturing and our status as an AS9100-certified machine shop. But the requirements on this project were particularly tough:
Fast turnaround to recover lost time on a slipping schedule
High-volume machining, with thousands of complex parts required
Tight tolerances, with several features in the tenths
Intricate features that demanded a careful machining strategy
Material had to be sourced domestically, adding another challenge in procurement
The customer not only wanted a fast first shipment, they were also looking for repeat production and predictability long-term. We aligned on a blanket order agreement and built a plan that met their scheduling needs and supported steady production.
The First Steps: Proven Process in Days, Parts in a Week
To meet their timeline, we dove in fast, taking several steps simultaneously. Material sourcing began immediately, and we started programming and process planning in parallel so we wouldn’t lose time waiting for other steps to finish.
Because the customer required material to be sourced domestically, there was additional complexity in procurement. We leaned on our trusted supplier relationships to locate the right material to meet their requirements. We also quickly obtained the best tooling for the part’s geometry.
Our Mazak mill-turn was the clear fit for the part, combining operations for maximum efficiency. Within days, we established a proven process because of our immediate action and preparation. Within a week, we were able to provide initial samples for customer review. After first article approval, we were ready to scale fast.
The Result: Unattended Production, Day Shift to Lights-Out
We quickly entered production, and the customer received exactly what they needed: quality parts delivered reliably. Months later, we’re still running the job both unattended during the day and lights-out at night. Several times each day, we inspect a part complete, and we’ve seen that our machine has held tolerances without issue.
Over time, our efficiency has helped the customer make up time for a project that they were once falling behind on. And because we’ve been able to machine ahead, they even have a buffer with our inventory, in case of unexpected needs in coming months.
High-Volume Machining for Your Next Project
If your next project involves high quantities, tight tolerances, and a fast timeline, the right manufacturing partner is critical. This job is just one example of how Tool Tech is a great match.
It challenged us in multiple dimensions, including speed, precision, complexity, and sourcing, but ultimately the outcome was straightforward: quality parts and a satisfied aerospace customer.
Do you have a demanding project coming up? Contact us to discuss capacity and lead times with our Massachusetts machine shop!