Case Study: How Advanced Workholding Reduced Cycle Times by 40%

In modern CNC machining, incremental improvements can make the difference between profit and loss. While most machine shops invest heavily in faster machines, better tooling, and advanced CAM software, the real game-changer often comes from optimizing something more fundamental: workholding.

This case study examines how one mid-sized manufacturing company achieved a 40% reduction in cycle times by adopting advanced workholding technologies, specifically self centering vises, CNC with 4th axis capabilities, and 5th axis vises. The improvements didn’t just come from faster cutting — they were the result of smarter setups, reduced handling, and consistent part positioning.

Company Background

The subject of our case study is a precision manufacturing firm specializing in components for the aerospace and medical industries. With 20 CNC machines running two shifts per day, they produce a mix of short-run prototype jobs and medium-volume production orders.

Before the upgrade, their average setup time per job was 45 minutes, and multi-sided parts required multiple re-clamp operations. This caused bottlenecks on their busiest machines and limited the number of jobs they could complete in a week.

The Challenge

The company faced three main pain points:

1. High Setup Times: Manual alignment and fixture changes slowed down throughput.
   
2. Positioning Inconsistency: Operators often spent time adjusting parts to meet tight tolerances.
   
3. Multi-Sided Machining Delays: Rotating parts manually introduced errors and wasted minutes each cycle.
   

To solve these issues, management decided to explore new workholding technologies that could integrate seamlessly into their existing workflow.

Step 1: Eliminating Manual Centering

One of the first upgrades was the introduction of a self centering vise on machines dedicated to symmetrical and mirrored parts. This simple change had an immediate impact:

• Parts were automatically centered to the machine’s axis without manual adjustments.
  
• Operators no longer needed to measure each setup.
  
• The risk of misalignment was significantly reduced.
  

As a result, setup times for these parts dropped from 15 minutes to under 5 minutes. The change also improved repeatability between batches, which meant less time spent on in-process inspections.

Step 2: Adding a CNC with 4th Axis

For parts requiring machining on multiple sides, the shop had been relying on traditional three-axis CNCs, which required manual repositioning. By upgrading to a CNC with 4th axis, the team could rotate parts automatically without removing them from the vise.

Impact:

• Reduced re-clamping steps from three down to one.
  
• Maintained exact datum points between operations.
  
• Allowed complex features to be cut in a single program cycle.
  

This change cut the average production time for multi-sided parts by 25%, freeing up machine capacity for more jobs each week.

Step 3: One-and-Done Machining with 5th Axis Vises

For the most complex aerospace parts, multiple setups were unavoidable — until the shop invested in 5th axis vises. These vises provided excellent tool clearance, enabling the machine to reach nearly every surface in a single clamping.

Results:

• Reduced setup counts from as many as five to just one.
  
• Minimized tolerance stack-up issues.
  
• Increased confidence in running lights-out machining for long cycles.
  

The adoption of 5th axis vises also meant the shop could take on more complex contracts that were previously too time-consuming to produce profitably.

Quantifiable Results

After six months of using advanced workholding, the company recorded the following improvements:

• Setup Time Reduction: 40% overall.
  
• Cycle Time Reduction: 20–50% depending on part complexity.
  
• Operator Efficiency: Less downtime between jobs and fewer errors.
  
• Capacity Increase: The ability to take on 15% more jobs per month without buying new machines.
  

Lessons Learned

The company identified several key takeaways from their investment:

1. Workholding Matters: Faster machines are useless if the setup is slow.
   
2. Integration is Key: Equipment upgrades should fit into the existing workflow with minimal disruption.
   
3. Operator Training is Essential: Even with automation-friendly vises, proper usage and maintenance are critical to consistent performance.
   

Conclusion

This case study demonstrates that optimizing workholding is one of the most effective ways to boost productivity in CNC machining. By incorporating a self centering vise, upgrading to a CNC with 4th axis, and deploying 5th axis vises, the shop didn’t just speed up machining — it transformed its entire production workflow.

For any manufacturer aiming to compete in high-precision, high-demand markets, workholding shouldn’t be an afterthought. It’s the foundation of accuracy, efficiency, and long-term profitability.