Case Study: Aerospace Engine OEM achieves 95% faster tool change-outs and 50x longer tooling life with Belcan

Manufacturing Optimization

Belcan worked with Aerospace Engine OEM, one of the largest aerospace engine manufacturers in the world, to address persistent production tooling problems in a piercing operation. The customer faced 10-hour tool change-outs, premature tool failures, duplicate tooling costs, expensive repairs, inflated inventory, and heavy burr formation.

Belcan identified that the piercing tool lacked adequate clearance and was causing large burrs and early failure. Belcan redesigned the blanking dies with proper clearances and a modular punch concept, including an interchangeable punch insert that could be quickly replaced when sharpened. The results included a 95% reduction in tool change-out time, more than 50x longer tooling life, elimination of heavy burrs, reduced inventory, restored lead times, removal of tool room repair needs, and an estimated $2.8 million in savings over five years.