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48665 Structural Drive, Chesterfield Township, MI 48051-2666

CASE STUDIES

CASE STUDY #1: Spg820

CHALLENGE

The customer had a quote for a nonstandard special milling cutter with a 1.100 IC insert, delivered in 14–18 weeks from an international source.

SOLUTION

Knight ran the numbers and found that a .950 IC depth of cut would work, easily accomplished with a readily available 1-inch IC insert.

RESULTS

  • Test inserts were delivered in just 5 weeks
  • Cost was reduced by 30% 
  • The tool was a success and follow-up order has already been placed. 

CASE STUDY #2: Poly V

CHALLENGE

After repeated delays from their usual supplier, this customer was looking at a 12-week lead time for urgently needed inserts. Their search for a new source led them to Knight Carbide.

SOLUTION

Knight was able to fulfill the order in our standard 7-week lead time. Plus, we were able to expedite the first 100 pieces in just 4 weeks.

RESULTS

  • Knight was able to deliver in less than half the time quoted by the original supplier. 
  • Plus, our quality was far superior–insert teeth profile rejections went from 35% on average for the previous supplier to ZERO rejections of Knight Carbide inserts. 
  • Tool life increased 25% with Knight Carbide inserts over those of the previous supplier. 
  • Within two weeks of shipping the first order, the customer had placed a repeat order, plus orders for two more products.

CASE STUDY #3: Spline Insert

CHALLENGE

A special spline tool insert by a major tool manufacturer was to be discontinued after 12 years, leaving the customer in the lurch.

SOLUTION

Starting with the insert they used the most, Knight re-engineered the production process to be faster and more efficient.

RESULTS

  • Cost reduced by 15%
  • Tool life increased by 20% 
  • Customer eliminated 1 tool change from production process
  • Customer switched other styles to Knight Carbide inserts

CASE STUDY #4: Delayed Specials

CHALLENGE

A large production plant had used over 20 different specials from a major tool producer over the past two decades, but delays were becoming a problem.

SOLUTION

Knight was able to produce and deliver the first detail in 4 weeks for a key distributor partner.

RESULTS

  • Knight has become the preferred supplier. 
  • Multiple orders for each insert have resulted in 15 details produced so far. 

CASE STUDY #5: Special Milling Tools and Inserts

CHALLENGE

A customer requested full design of milling tools and inserts to machine specialty valves for their products.

SOLUTION

From the customer-provided part print, Knight was able to design a special cutter and inserts to create the required geometry.

RESULTS

  • Orders have been received for 3 different tools for one size part and another order for the next size up. 
  • Potential for 100-plus tools over the course of the project

CASE STUDY #6: Special Top Notch Inserts

CHALLENGE

Long deliveries on special top-notch inserts.

SOLUTION

Having semi-finished inventory and being set up for a made-to-order process, Knight was able to expedite the special insert from on-hand standards.

RESULTS

  • Quick turnaround resulted in multiple orders.