When Digital Machining Systems (DMS) wanted to reduce their cost of tooling for making port plug screws with T-15 tools from two competitors on a CNC lathe, the Louisiana-based small parts components manufacturer turned to us for assistance.

After finding us through an online search, DMS has been benefitting from the quality of the Hassay MAX broaching tools we manufacture. Over the past six months, the company has also taken advantage of our Tooling Concierge service which leverages our technical knowledge to connect customers with the ideal broaching tools, reamers, micro endmills & drills, and more for their specific applications.

Hassay Max after machining 150 parts

In a case of exceeding expectations, DMS’s engineers experimented and successfully doubled the recommended feed rates of 3.5 IPM to 7 IPM. The Hassay MAX broach is outperforming the benchmarks that we thought it is capable of.

“Pilot has impressed us with their unique combination of quality products and technical expertise,” says Eric Terradot, Tooling Manager at Digital Machining Systems “They take a hands-on approach that has added considerable value to our operations.”

Background

After asking a battery of questions that allowed us to develop a thorough understanding of DMS’s application, we recommended that the customer switch to a Hassay MAX rotary broaching tool from tooling he had been using.

HassayMAX tool after machining 95 parts

DMS took our advice because our broach provides longer tool life at a comparable cost to what they pay for the tooling being used. As a result of the increased tool life our hexagonal rotary broaches offer, DMS is experiencing these benefits:

• 12.5x more parts machined per tool
• Better edge toughness
• 90%+ reduction in cost per part
• 93% reduction in monthly productivity losses
• 50% improvement in cycle times
• 100% improvement in feed rates (IPM)
• Monthly cost savings of more than $5,000

What the Future Holds

After having problems with another manufacturer’s tool holder, DMS is exploring the possibility of purchasing tool holders from us while continuing to reap the advantages of our hex rotary broaches.

Eric Terradot will not use any other rotary broach and will be using our tools in all applications moving forward, even in Stainless Steel parts they make.

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