D&E Machining Improves Setup Times

Client Profile:

D&E Machining machines various materials, including steels, cast iron, non-ferrous, exotics, and plastics. The company was founded in 1993 and currently employs 50 people at its facility in Corry, PA.


D&E Machining wanted to improve the setup times on its CNC bar machines, which traditionally have the highest scrap rate, and turned to Operations Strategy Consulting (OSC) for assistance.


Megan Burns, of OSC, began by spending time on-site understanding the process and manufacturing flow. Then Megan worked with the CNC operators to observe two different setups to establish a baseline. Based on the observations, OSC worked with the D&E Machining team to analyze the setups and identify steps to reduce the setup times on the bar machines. The team then worked to implement many of the improvements. When the team observed a comparison setup after implementing just half of the improvement ideas, they realized a reduction in setup times by 20 percent. The team anticipated a further reduction of another 20 percent once all the improvements had been implemented.


  • Reduced setup times by 20 percent.
  • Projected savings of $10,000.
We have experienced a significant reduction in setup time, which will lead to significant cost savings. Operations Strategy Consulting’s encouragement during the term of the project helped ensure its success. Ron Holl, President/Owner

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