SOLUTIONS

PROBLEM – reduce costs to make a hardened Bearing Roller.

DESCRIPTION - The Bearing Rollers are hardened to 400 BHN and they had to cylindrical grind the profile on each one to hold the tight tolerances specified.

SOLUTION = We broke down the entire process from start-to-finish and came up with a pre-machining, heattreat, then final machining process utilizing advanced hard tooling that eliminated cylindrical grinding.

BENEFITS: Costs savings of 30% and reduced lead time from 56 days to 34 days.

PROBLEM – find a way to make a hardened Cam Roller without Jig Grinding.

DESCRIPTION - The Rollers are flame hardened to 54 RC minimum and the old process used fixtures and jig grinding to complete the profile and hold the tight tolerances.

SOLUTION = We assessed the existing process and heattreating; then altered all processes to eliminate jig grinding by hard milling with advanced tooling.

BENEFITS: Costs savings of 10% and reduced lead time from 54 days to 28 days.

PROBLEM – reduce the time needed to complete complex hardened Cam Roller.

DESCRIPTION – lead time to complete the finish machining operations was 2 weeks longer than the market would accept.

SOLUTION = Create a Supermarket to hold parts in a semi-finished state, implement a velocity program giving these parts priority shop scheduling.

BENEFITS: Reduced lead time from 24 days to 14 days.

PROBLEM – Customer had a cast iron Gearbox that was worn out and non-functioning. Specification and drawings were available from the OEM.

DESCRIPTION – The Gearbox was originally manufactured before 1940 as a casting. The casting patterns were not available and new patterns were expensive with a long lead time.

SOLUTION = We converted the cast iron Gearbox into a fabrication and supplied a complete unit assembly including all Gears, Shafts, Bearings, pumps, lube lines, etc.

BENEFITS: Cost savings of 60% from pattern and casting alone and reduced lead time by 30 weeks.

PROBLEM – Customer had a pair of large Bronze Nuts with the internal threads wore out. Specification and drawings were not available from the OEM.

DESCRIPTION – Each Bronze Nut weighed 3,000 LBS and was assembled onto a large hydraulic press 50 feet up in the air. Customer could not afford to take the machine down for repairs, or remove the Nuts for reverse engineering.

SOLUTION = We took our portable FARO CMM Arm to the Customer’s site, went to the top of the press and took readings on the threads. We then made a split Aluminum sample Nut to test our readings on the actual threads. After a few minor adjustments, we machined the new Bronze Nuts and delivered to the Customer on time.

BENEFITS: Priceless – these large Nuts were not available from the OEM Manufacturer and without replacements the press would have gone down permanently.

PROBLEM – provide a standard napkin roll with interchangeable Customer logos

DESCRIPTION – Typically every fast food Customer has their own logo on their napkins, however the napkins themselves are similar.

SOLUTION = We machined a pocket into the napkin roll for a logo plate, then machined different logo plates to fit into that pocket for interchangeability

BENEFITS: Cost savings, reduced roll inventory and faster tooling changes for the Converting Customers.