MetalFabBlogpdf
MetalFabBlogpdf
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  1. BOOSTING PRODUCTIVITY & STREAMLINING FINISHING WITH PSG EXTREME II FLAP DISCSTHE CHALLENGEBefore contacting CGW, this fabrication facility used a zirconia poly/cotton blend flap disc in 36 grit for initial weld remov-al, then switched to an 80 grit disc to remove scratches and prepare the metal for powder coating. This two-step approach slowed production, required multiple product SKUs, and increased costs. Additionally, each welder preferred a different abrasive brand, leading to inconsistency and inflated inventory.Key Issues:●Two-step grind-and-finish process with grit 36 then grit 80●Inconsistent product usage and excessive SKUs●Higher labor and consumable costs due to slow material removal and disc wearTHE CGW APPROACHOur team visited the shop floor to analyze their current process, machinery, and specific weld angles. We then conducted a live demonstration using a single grit of our PSG eXtreme II Flap Discs—known for high stock removal rates, cooler grinding temperature, and extended disc life.1. Consolidated Grits: We recommended switching to 60 grit PSG eXtreme II, eliminating the need for separate 36 and 80 grit discs.2. Unified SKUs: We helped the facility standardize abrasives across all welding stations, cutting down from eight different SKUs to two.3. Interleaf Introduction: For specific projects requiring a #4 finish, we showcased CGW’s Interleaf Flap Discs. This replaced the three products they were using previously to achieve the same result, further simplifying inventory.4. Onsite Training: We provided free training sessions on proper flap disc usage, blend techniques, and recommended RPM adjustments, ensuring each welder felt confident and safe.At CGW Abrasives, we believe that partnering with end users—even though we sell through distributors—is the best way to truly understand application challenges and deliver the right solutions. This case study features a leading Midwest manufacturer of ladders, stair railings, and steps. Their fabri-cation process needed a productivity boost without sacrific-ing finish quality. By tapping into CGW’s free onsite process improvement, technical field support, and training
  2. About CGWCGW is a leading manufacturer of premium grinding wheels, cutting wheels, and abrasive products. With a commitment to quality and innovation, we provide solutions that enhance productivity and efficiency for fabricators worldwide.THE RESULTSWHY PSG EXTREME II FLAP DISCS?Our PSG eXtreme II Flap Discs are engineered for superior performance on carbon steel, stain-less steel, and other metal alloys. With preci-sion-shaped grains, they cut cooler and maintain a sharper grinding edge longer than traditional zirconia discs. This translates to fewer operator adjustments, reduced downtime, and optimal surface finishes—all critical factors in high-volume production environments.PARTNER WITH CGW ABRASIVESThis success story underscores our commitment to free process improvement services, technical field support, onsite training, and cost-savings analysis. We believe the best way to serve our customers—large or small—is through active collaboration on the shop floor.If you’re looking to streamline your fabrication process, improve productivity, and achieve consistent finishes, reach out to our team. We’re ready to roll up our sleeves, provide product demonstrations, and customize a solution that fits your unique needs.READY FOR A PRODUCTIVITY BOOST?Contact us or speak with your local distributor to explore how PSG eXtreme II Flap Discs and our field support can transform your operation.By adopting the 60 grit PSG eXtreme II Flap Disc, the customer achieved 40% faster weld removal compared to their old 36 grit zirconia disc—while still leaving a finish comparable to 80 grit. This time savings effectively doubled throughput by consolidating two steps into one.Key Outcomes:●Higher Removal Rate: 40% faster material removal than competitor’s 36 grit●Better Finish: Comparable to 80 grit, eliminating a second grinding step●Twice the Disc Life: Fewer changeovers and reduced consumable costs●Simplified Inventory: From eight SKUs down to two main products●Improved Safety & Efficiency: Onsite training maximized usage and minimized errors
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