Problem: As KLAW Industries scaled production of Pantheon, hammer replacement became one of our largest operating costs and sources of downtime. Our industry-standard hammers lasted only 3–4 days and cost over $1,500 per replacement, making frequent maintenance expensive and disruptive.

Solution: After confirming that our equipment was operating correctly, I determined that conventional hammer materials could not withstand the highly abrasive glass we processed.

I developed a systematic testing program, evaluating more than 10 materials from suppliers across four countries. After multiple rounds of testing and design improvements, we developed a hammer that lasted six weeks instead of 3-4 days and cost 40% less per replacement, extending service life by more than x10 while significantly reducing production costs and downtime.

Steps Taken

1) Identify Root Cause - Investigated premature hammer wear and verified operating conditions, determining that the primary issue was material durability rather than improper equipment operation.

2) Develop Testing Methodology - Established a metrics-driven testing process to compare hammer materials based on service life, replacement costs, downtime, and overall impact on cost of goods sold (COGS).

3) Source and Test Materials - Identified suppliers in the United States, Canada, China, and Mexico, and conducted production trials of more than 10 different hammer materials.

4) Optimize Material and Design - Analyzed trial results and worked through multiple iterations with suppliers to improve hammer material composition, geometry, durability, and cost.

5) Implement Final Design - Selected and implemented the optimized hammer design, increasing replacement intervals from 3-4 days to six weeks while reducing the cost per replacement by 40%.