Case Study: BC Machining achieves tool failure prevention and scrap reduction with MachineMetrics Tool Monitoring

BC Machining - Customer Case Study

BC Machining, a domestic production facility in Brasstown, NC, was struggling with excessive scrap on its 24-hour CNC Swiss lathes. Running machines at 200% capacity led to broken endmills, significant scrap costs, and no visibility into when tool wear or breakage was about to occur. To address the issue, they turned to MachineMetrics and its Tool Monitoring solution.

MachineMetrics implemented adaptive tool monitoring to detect warning signals before catastrophic failures on BC Machining’s STAR SR-20 machines. The system identified imminent tool breakage with 99% accuracy and automatically triggered feedholds to stop machines before scrap was produced. As a result, BC Machining virtually eliminated scrap from tool wear and achieved an estimated $72K in annual savings per machine.

BC Machining

Bob Merrill

Owner