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Turn Abrasive Performance Into Business Results

Weiler Consumable Productivity (WCP) uses real-world testing to identify opportunities to save time, improve productivity and reduce total operating costs.

A Practical Approach to Measurable Improvement

The true cost of an abrasive goes beyond its purchase price. Product life, changeovers, labor and throughput can all affect your operation.

Our abrasives experts work alongside your team to understand the current process, test recommended solutions and document their impact. The result is a clearer view of which changes could deliver the greatest value.

Measured Results Across Metal Fabrication Operations

Through WCP, we have helped customers recover labor hours, improve productivity and reduce total operating costs.

341,023
Labor Hours Recovered
$ 24,784,700
Total Savings Identified (MXN)

Results reflect WCP assessments performed since February 2024. Savings and labor-hour figures represent the estimated annual impact based on measured test results.

How We Find Savings in Your Operations

Through a simple yet effective approach, we identify improvements by evaluating your operations and how abrasives are used in your facility.

Expert consulting with a metalworker.

On-site Assessment

On-site Assessment

We come to your facility to understand your production processes, priorities and challenges firsthand.
Right angle grinder with grinding wheel on a metal workpiece.

Establish a Baseline

Establish a Baseline

We measure how your current abrasives perform to establish a fair benchmark for comparing improvements.
Scale weighing a grinding wheel for an abrasive test.

Test and Measure

Test and Measure

We test the recommended solutions, measuring the time it takes, how many parts are completed, and how many consumables are used.
Clipboard with test results.

Calculate Impact

Calculate Impact

We translate the test results into estimated annual cost savings and labor hours your team could put toward other work.
Expert showing results to a plant manager.

Present the Results

Present the Results

We review the findings with your team and explain which changes could deliver the greatest value in your operation.
Expert consulting with a metalworker.

On-site Assessment

On-site Assessment

We come to your facility to understand your production processes, priorities and challenges firsthand.
Right angle grinder with grinding wheel on a metal workpiece.

Establish a Baseline

Establish a Baseline

We measure how your current abrasives perform to establish a fair benchmark for comparing improvements.
Scale weighing a grinding wheel for an abrasive test.

Test and Measure

Test and Measure

We test the recommended solutions, measuring the time it takes, how many parts are completed, and how many consumables are used.
Clipboard with test results.

Calculate Impact

Calculate Impact

We translate the test results into estimated annual cost savings and labor hours your team could put toward other work.
Expert showing results to a plant manager.

Present the Results

Present the Results

We review the findings with your team and explain which changes could deliver the greatest value in your operation.
Talk to an Expert

WCP: Improves Total Operating Costs

When was the last time you measured the total operating costs associated with your abrasive consumables? 

Inefficiencies in metal fabrication production can lead to unnecessary downtime, labor constraints, bottlenecks, and even overspending.  

From foundry cleaning rooms to fab shops, there is a strong desire to find cost savings and productivity improvements, but most lack the resources to optimize their cutting and grinding operations. 

Schedule an On-site Assessment

The first step to finding cost and time savings is to schedule a free on-site assessment where Weiler experts will evaluate how our abrasives can eliminate inefficiencies, safety issues, and labor shortages in your operation. 

Resources:

Our Approach

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On-site Assessment

On-site Assessment

On-site Assessment: We come to your facility to walk the shop floor and learn about your production process firsthand. Once we understand your priorities and challenges, we select the most appropriate products and create a plan for testing.
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Establish a Baseline

Establish a Baseline

Establish a Baseline: To make recommendations based on facts, we establish a baseline by capturing data on the current process
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Testing

Testing

Testing: During testing, we measure the time it takes, how many parts are completed, and how many consumables are used.
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Calculate Impact

Calculate Impact

Calculate Impact: Using the collected data, we estimate annual savings based on labor, time, and consumable consumption. 
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Presenting Improvement

Presenting Improvement

Presenting Improvement: We then present the test results and provide documented cost and time savings based on our recommendations.
400x225-heilicalgeargrindappcolor

On-site Assessment

On-site Assessment

On-site Assessment: We come to your facility to walk the shop floor and learn about your production process firsthand. Once we understand your priorities and challenges, we select the most appropriate products and create a plan for testing.
350x350-carousel3

Establish a Baseline

Establish a Baseline

Establish a Baseline: To make recommendations based on facts, we establish a baseline by capturing data on the current process
350x350-carousel3

Testing

Testing

Testing: During testing, we measure the time it takes, how many parts are completed, and how many consumables are used.
350x350-carousel3

Calculate Impact

Calculate Impact

Calculate Impact: Using the collected data, we estimate annual savings based on labor, time, and consumable consumption. 
350x350-carousel3

Presenting Improvement

Presenting Improvement

Presenting Improvement: We then present the test results and provide documented cost and time savings based on our recommendations.

See How Much You Could Save

Improvements in abrasive life and productivity can add up. Use our calculator to estimate the potential impact on your operating costs.

Laptop showing abrasives savings calculator.

Proven on the Shop Floor

See how we work alongside your team to solve application challenges, recover productive time and reduce operating costs.

Eliminating a Production Step at J.C. Steele

We looked beyond the abrasive and worked alongside J.C. Steele to understand the entire operation. Through WCP, we identified an opportunity to eliminate a production step and improve productivity.

Watch the video to see partnership in action.

Uncover $108K+ in Projected Annual Savings

WCP on-site test for grinding wheels.

We worked alongside a container repair team to compare abrasives under its actual working conditions, identifying more than $108,000 in projected annual savings and 1,190 labor hours available for other work.

Increase Cleaning Throughput by 50%

Strip disc cleaning metal.

We tested solutions on a pipe coating operation’s production floor, demonstrating 50% more cleaning output and identifying $13,723 in annual abrasive savings.

Reduce Abrasive Use and Save $53,500

3D Max resin fiber disc grinding a weld.

We looked beyond the abrasive and identified a backing pad issue that was limiting performance. With the right disc, backing pad and grinding technique, the operation removed 32% more material and used 8,400 fewer discs annually.

Look Beyond the Abrasive

"We don’t just swap out abrasives. We look at the process and find a better way to do it. Matching the right product to the shop’s equipment and materials is key. If we can eliminate steps in the production process, we can provide even greater value to our customers."

- John Sockman
Director of End User Sales, Weiler Abrasives

Where Could Your Operation Improve?

Weiler Abrasives is an industry leader and global manufacturer of surface conditioning solutions. We are eager to create a collaborative partnership to overcome your toughest cleaning, grinding, cutting, de-burring, and finishing challenges.