Carr Tool: Our Process

Quoting
Order Entry
Work Scheduling
Our Equipment

To increase efficiencies throughout our shop, Carr Tool has invested nearly $2,000,000 in New CNC machines. These CNC machines will allow us to continue to improve our quality and repeatability while reducing our manufacturing time, enabling us to pass even greater cost savings on to our customers.

CNC Turning Center Department
Mazak Quick Turn 250
Mazak Quick Turn 15N

CNC Milling Department
(1) Haas VF3 (5 AXIS)
(2) Bohle Flutemaster
(1) Hardinge VMC 1000

CNC Cutter Grinder Department
ANCA TX7
ANCA RGX
ANCA TG7

CNC-OD Grinder Department
Trutech

Braze Department
Induction Brazing Pillar
MK-20

Deep Hole Drilling
Eldorado Gun Drill

Our Equipment

After Engineering completes scheduling, the job moves into the shop. Perishable tooling and raw materials are pulled and packaged along with a complete printout of the work instructions, manufacturing drawing, and job routing schedule from the E2 Shop System. Certifications and lot numbers for all raw materials are maintained and recorded for product identification and traceability.

The job is then staged through each machining station: Turning Centers, Mills, OD Grinders, and Cutter Grinders. Before beginning the manufacturing process, the operator scans in the appropriate barcode for his portion of the work to be done. Unique barcodes are assigned for each job and for each machine in the shop. By scanning the barcodes into the E2 system, the progress of every job throughout the shop is instantly known.

As part of Carr Tool's commitment to superior quality, In-Process Inspections of the first and last piece of each job are conducted at every machining operation. Additionally, random product audits and machine capabilities studies are performed throughout our manufacturing process. We also maintain statistical process control (SPC) charts on all of our machines.

Upon completion of the manufacturing process, the job goes to our Final Inspection department where a variety of diameter analyses and tolerance checks are performed according to established checklists for each type of tool we machine. Our dedication to exemplary quality in every tool we make has led to a less than one percent customer rejection rate of our tools in the field.

Inspection equipment used throughout our manufacturing process includes:

Optical Comparators
Super Micrometers
Laser Micrometers

PG-1000 Surface Illumination Device (Creates high-definition images of the finished tool surface; also used by Engineering to assist in the diagnosis of customer tooling problems.)

Final Inspection reports for every tool we make are kept on file at Carr Tool. A copy of the Final Inspection report can be shipped with the finished tools when the customer requests it. All finished tools are etched with a job number, drawing number, and shipping date, and then carefully packed for shipping. We ship via both UPS® and FedEx®, which are also integrated into the E2 system for online tracking.