Case Study: How a Manufacturer Reduced Grinding Costs by 20%

Grinding operations are a major expense in metal fabrication, construction, and stone processing. Between abrasive wheels, labor time, and machine wear, the costs add up quickly.

This case study highlights how a mid-sized manufacturer achieved a 20% reduction in grinding costs without sacrificing quality—simply by rethinking their abrasive wheel strategy.

1. The Problem

The manufacturer, a metal parts supplier, faced three major issues:

• High wheel consumption: Cheap wheels wore out quickly, leading to frequent replacements.

• Slow productivity: Operators needed multiple passes to achieve a clean finish.

• Frequent downtime: Machine vibration and wheel imbalance caused maintenance interruptions.

On paper, the company was saving money by purchasing low-cost cutting discs. In reality, hidden costs eroded profitability.

2. The Approach

To address these challenges, the company took a three-step optimization approach:

1. Wheel Selection

• Switched from low-cost wheels to a higher-quality abrasive wheel with a softer bond for stainless steel.

• Selected the correct grit size (medium grit) for balanced speed and finish.

2. Process Optimization

• Adjusted feed rate and cutting pressure.

• Introduced proper coolant use to reduce overheating.

3. Equipment Maintenance

• Balanced machine spindles to minimize vibration.

• Improved operator training to prevent misuse.

3. The Results

After three months of implementation, the company recorded:

• 20% overall cost reduction in grinding operations

• 40% fewer wheel replacements due to longer lifespan

• 15% higher productivity thanks to faster, cleaner cuts

• Less downtime, leading to improved on-time delivery

Conclusion

Cutting costs in grinding isn’t about finding the cheapest wheel. It’s about choosing the right wheel, optimizing the process, and maintaining the equipment.

This manufacturer’s 20% cost reduction proves that investing in quality and efficiency delivers real savings over time.