Tool inventory management for MNMUK machine shop. Tracks tooling, inserts, consumables with reorder points and usage. USE WHEN user asks 'tool inventory', 'what inserts', 'reorder', 'tool crib', 'do we have', 'tooling cost', or 'tool usage'.
Purpose: Track tooling inventory, prevent stockouts, control costs, optimize usage.
| Category | Examples | Typical Stock |
|---|---|---|
| OD Roughing | CNMG, WNMG, DNMG | 20-50 per grade |
| OD Finishing | DCMT, VCMT, CCMT | 10-30 per grade |
| Boring |
| CCMT, TCMT, DCMT |
| 10-20 per size |
| Threading | 16ER, 16IR (various pitches) | 5-10 per pitch |
| Grooving/Parting | Various widths | 10-20 per width |
| Copy turning | VCMT, DCMT | 10-20 per grade |
| Category | Examples | Typical Stock |
|---|---|---|
| Face milling | APKT, SEKN, ODMT | 20-40 per grade |
| Shoulder milling | APMT, LOGU | 10-30 per grade |
| Slot/pocket | APMT, various | 10-20 per size |
| Category | Sizes | Typical Stock |
|---|---|---|
| Endmills (3-flute) | Ø3-20mm | 2-5 per size |
| Endmills (4-flute) | Ø6-25mm | 2-5 per size |
| Ball nose | Ø3-16mm | 1-3 per size |
| Drills | Ø1-20mm (0.5mm steps) | 2-5 per size |
| Reamers | Common sizes | 1-2 per size |
| Taps | M3-M20 | 3-10 per size |
| Thread mills | Common pitches | 1-2 per size |
| Category | Types |
|---|---|
| Turning | External, internal, threading, parting |
| Milling | Shrink fit, ER collet, hydraulic, side-lock |
| Boring | Modular boring bars, cartridge heads |
| Item | Track |
|---|---|
| Collets (ER, 5C, etc.) | By size |
| Chuck jaws | By chuck/type |
| Parallels, V-blocks | General stock |
| Workholding clamps | By type |
| Edge finders, indicators | Per machine |
| Gauge pins, thread gauges | By size/pitch |
# Insert Inventory
Last Updated: YYYY-MM-DD
Counted By: [Name]
## Turning Inserts
| Insert Code | Grade | Qty In Stock | Min Stock | Reorder Qty | Location | Last Count | Supplier | Cost Each |
|-------------|-------|--------------|-----------|-------------|----------|------------|----------|-----------|
| CNMG120408-PM | 4325 | | 20 | 50 | A1-01 | | Sandvik | £X.XX |
| CNMG120408-MR | 4325 | | 20 | 50 | A1-02 | | Sandvik | £X.XX |
| WNMG080408-PM | 4325 | | 10 | 30 | A1-03 | | Sandvik | £X.XX |
| DCMT11T304-PF | 4325 | | 10 | 30 | A1-04 | | Sandvik | £X.XX |
| VCMT110304-PF | 4325 | | 10 | 20 | A1-05 | | Sandvik | £X.XX |
| 16ER-1.5ISO | 4325 | | 10 | 20 | A2-01 | | Sandvik | £X.XX |
| 16IR-1.5ISO | 4325 | | 5 | 10 | A2-02 | | Sandvik | £X.XX |
## Milling Inserts
| Insert Code | Grade | Qty In Stock | Min Stock | Reorder Qty | Location | Last Count | Supplier | Cost Each |
|-------------|-------|--------------|-----------|-------------|----------|------------|----------|-----------|
| APMT1135-PM | 4240 | | 20 | 50 | B1-01 | | Sandvik | £X.XX |
| SEKN1203 | 4240 | | 10 | 30 | B1-02 | | Sandvik | £X.XX |
## Solid Carbide - Endmills
| Description | Diameter | Flutes | Coating | Qty | Min | Location | Supplier | Cost |
|-------------|----------|--------|---------|-----|-----|----------|----------|------|
| GP Endmill | Ø6mm | 4 | AlTiN | | 3 | C1-06 | | £XX |
| GP Endmill | Ø8mm | 4 | AlTiN | | 3 | C1-08 | | £XX |
| GP Endmill | Ø10mm | 4 | AlTiN | | 3 | C1-10 | | £XX |
| GP Endmill | Ø12mm | 4 | AlTiN | | 3 | C1-12 | | £XX |
| SS Endmill | Ø6mm | 5 | TiAlN | | 2 | C2-06 | | £XX |
| SS Endmill | Ø8mm | 5 | TiAlN | | 2 | C2-08 | | £XX |
## Drills
| Type | Diameter | Coating | Qty | Min | Location | Supplier | Cost |
|------|----------|---------|-----|-----|----------|----------|------|
| Carbide | Ø3.0mm | TiAlN | | 5 | D1-30 | | £XX |
| Carbide | Ø3.5mm | TiAlN | | 5 | D1-35 | | £XX |
| Carbide | Ø4.0mm | TiAlN | | 5 | D1-40 | | £XX |
| Carbide | Ø4.5mm | TiAlN | | 5 | D1-45 | | £XX |
| Carbide | Ø5.0mm | TiAlN | | 5 | D1-50 | | £XX |
Reorder Point = (Daily Usage × Lead Time) + Safety Stock
Where:
- Daily Usage = Monthly usage ÷ Working days
- Lead Time = Supplier delivery days
- Safety Stock = 1-2 weeks usage (critical items)
# Tool Reorder Report
Generated: YYYY-MM-DD
## Items Below Minimum Stock
| Item | Current Qty | Min Stock | Reorder Qty | Supplier | Est. Cost | Priority |
|------|-------------|-----------|-------------|----------|-----------|----------|
| | | | | | | HIGH |
| | | | | | | MEDIUM |
| | | | | | | LOW |
## Total Reorder Value: £X,XXX
## Approval
| | |
|---|---|
| Requested By: | |
| Approved By: | |
| Date: | |
| PO Number: | |
| Supplier | Lead Time | Min Order | Account # | Contact |
|---|---|---|---|---|
| Sandvik | 2-3 days | £100 | ||
| Seco | 2-3 days | £100 | ||
| Iscar | 2-3 days | £100 | ||
| Kennametal | 3-5 days | £100 | ||
| OSG | 3-5 days | £50 | ||
| Cutwel | Next day | £25 |
# Insert Usage Log
## Month: [YYYY-MM]
| Date | Job # | Insert Code | Qty Used | Machine | Reason | Operator |
|------|-------|-------------|----------|---------|--------|----------|
| | | | | | Wear | |
| | | | | | Chipped | |
| | | | | | Broken | |
## Monthly Summary
| Insert Code | Total Used | Cost | Top Consumer (Job) |
|-------------|------------|------|-------------------|
| | | £ | |
| | | £ | |
**Total Insert Cost This Month: £X,XXX**
# Tool Cost Analysis - Job [Number]
| Tool | Insert/Item | Qty Used | Parts Made | Cost/Part | % of Total |
|------|-------------|----------|------------|-----------|------------|
| T1 | CNMG120408 | 4 | 500 | £0.XX | XX% |
| T2 | DCMT11T304 | 2 | 500 | £0.XX | XX% |
| T3 | Ø10 Drill | 1 | 500 | £0.XX | XX% |
| | | | | | |
| **Total** | | | | **£X.XX** | 100% |
**Target: £X.XX/part | Actual: £X.XX/part | Variance: XX%**
| Insert Type | Material | Expected Life (edges) | Notes |
|---|---|---|---|
| CNMG (rough) | Steel | 15-25 min/edge | 4 edges |
| CNMG (rough) | Stainless | 8-15 min/edge | 4 edges |
| DCMT (finish) | Steel | 20-40 min/edge | 2 edges |
| DCMT (finish) | Stainless | 10-20 min/edge | 2 edges |
| Threading | Steel | 50-100 threads/edge | |
| Endmill (carbide) | Steel | 60-120 min | Regrind 2-3x |
| Endmill (carbide) | Stainless | 30-60 min | Regrind 2-3x |
| Drill (carbide) | Steel | 500-2000 holes | Regrind 2-3x |
# Regrind Log
| Tool ID | Description | Diameter | Regrinds | Max | Status | Location |
|---------|-------------|----------|----------|-----|--------|----------|
| EM-001 | 4FL Ø12 AlTiN | 12.00mm | 0 | 3 | In use | M3-T5 |
| EM-001 | 4FL Ø12 AlTiN | 11.85mm | 1 | 3 | Stock | C1-12R |
| EM-001 | 4FL Ø12 AlTiN | 11.70mm | 2 | 3 | Stock | C1-12R |
| EM-002 | 4FL Ø10 AlTiN | 9.85mm | 1 | 3 | For regrind | Regrind box |
# Tool Crib Monthly Audit
Date: YYYY-MM-DD
Auditor: [Name]
## Physical Count vs. System
| Location | Items Counted | Discrepancies | Value Variance |
|----------|---------------|---------------|----------------|
| A - Turning inserts | | | £ |
| B - Milling inserts | | | £ |
| C - Solid carbide | | | £ |
| D - Drills | | | £ |
| E - Taps/reamers | | | £ |
| F - Holders | | | £ |
## Condition Check
| Issue | Items Found | Action Taken |
|-------|-------------|--------------|
| Damaged packaging | | |
| Corroded tools | | |
| Wrong location | | |
| Expired (shelf life) | | |
## Stock Optimization
| Item | Current Stock | 6-Month Usage | Recommendation |
|------|---------------|---------------|----------------|
| | | 0 | Remove from stock |
| | | Low | Reduce min level |
| | | High | Increase min level |
## Summary
| Metric | Value |
|--------|-------|
| Total SKUs | |
| Total Value | £ |
| Items below min | |
| Items overstocked | |
| Accuracy % | |
# Tooling Cost Report - [Month YYYY]
## Summary
| Category | Budget | Actual | Variance |
|----------|--------|--------|----------|
| Turning inserts | £ | £ | £ |
| Milling inserts | £ | £ | £ |
| Solid carbide | £ | £ | £ |
| Drills/taps | £ | £ | £ |
| Regrinding | £ | £ | £ |
| **Total** | **£** | **£** | **£** |
## Cost Per Machine Hour
| Machine | Hours | Tool Cost | £/Hour |
|---------|-------|-----------|--------|
| NMV3000 | | £ | |
| DMU50 | | £ | |
| NLX2500 | | £ | |
| CITIZEN | | £ | |
| **Average** | | | **£** |
## Top 10 Cost Items
| Rank | Item | Qty Used | Cost | % of Total |
|------|------|----------|------|------------|
| 1 | | | £ | |
| 2 | | | £ | |
| 3 | | | £ | |
## Cost Reduction Actions
| Action | Potential Savings | Status |
|--------|-------------------|--------|
| | £ | |
| Metric | Target | Notes |
|---|---|---|
| Tooling as % of sales | 3-5% | Industry benchmark |
| Tool cost per machine hour | £5-15 | Depends on materials |
| Insert cost per part | <2% of part cost | Target |
┌─────────────────────────────────────────────────────┐
│ TOOL CRIB │
├─────────┬─────────┬─────────┬─────────┬────────────┤
│ A │ B │ C │ D │ E │
│ Turning │ Milling │ Solid │ Drills │ Taps & │
│ Inserts │ Inserts │ Carbide │ │ Reamers │
├─────────┴─────────┴─────────┴─────────┴────────────┤
│ F │
│ Toolholders & Collets │
├─────────────────────────────────────────────────────┤
│ G │
│ Workholding & Fixtures │
├─────────────────────────────────────────────────────┤
│ REGRIND │ NEW STOCK │
│ BOX │ INTAKE │
└─────────────────────────────────────────────────────┘
Format: [Section][Row]-[Position]
Example: A1-05 = Section A, Row 1, Position 05
Sections:
A = Turning inserts
B = Milling inserts
C = Solid carbide endmills
D = Drills
E = Taps, reamers, thread mills
F = Toolholders
G = Workholding