Every step of the Carr Tool manufacturing process yields high quality tools, from the simple to the extremely complex, while providing exceptional quality, service, and value to our customers. Our goal is constant improvement.
Based on this philosophy, we've undertaken a major initiative to identify and eliminate production bottlenecks by working with our business partners over the years. We utilize the E2 Shop System from ShopTech Software Corporation to monitor every job in our workflow, from initial quoting to final delivery.
When you request a quote from Carr Tool, the specs and requirements for your job are first input into our shop management system. This allows us to price all quotes based on a database analysis of previous and current manufacturing process times and required materials. This recorded history of estimated versus actual hours and purchasing costs enables us to offer our customers more consistent pricing and lead times.
Typically, you will find your quote returned to you within a day or two. Once we receive your approval to proceed in the form of a purchase order, the job in entered into our system and routed to Engineering.
Upon receipt of your purchase order, the required information is entered into our manufacturing workflow routing system. All tool drawings and specifications are directed to our Engineering Department for a thorough analysis and a recommended routing plan with an estimated production time frame.
This analysis includes redrawing the original CAD drawing submitted by the customer to a standard format used by our shop to maximize handling efficiency by eliminating the need for operator interpretations. All specs are converted to English units of measure, and final drawings are stored both electronically and in hard copy formats for future reference.
Once the analysis is complete, machining processes are determined. The Engineering Department develops a shop routing schedule detailing the manner in which each job is processed, along with estimated times for each machining stage.
Additionally, our Engineering Department can design special and unique new tools as required by our customers.
A list of required raw materials to be used at each step is also generated within the manufacturing software and monitored by our Purchasing Department. Raw materials are ordered on a just in time basis, reducing overhead from maintaining excessive stock.
After Engineering completes the 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. Certifications and lot numbers for all raw material are maintained and recorded for product identification and traceability.
The job is then staged through each station: Turning Centers, Mills, OD Grinders, and Cutter Grinders.
As part of our commitment to superior quality, In-Process Inspections of the first and last piece of each job are conducted at every machining operation.
Upon completion of the manufacturing process, the job goes to our Final Inspection department where a variety of diameter and tolerance checks are performed according to established checklists for each type of tool.
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/tool number, and ship date, and then carefully packed for shipping. We ship via both UPS® and FedEx®.