Case Study: Streamlining Production and Improving Quality
Customer
Industrial Automation Manufacturer
Part
Box Lug
Manufacturing Issues
The existing production process required too many steps, which was driving up costs
Misalignment on the top of the part was decreasing the quality and performance of
the inner threads.
Customer’s Goals
Reduce production time with an improved manufacturing method.
Eliminate the thread quality issue without significantly increasing costs.
Manufacturing Process
First, Ultra focused on fixing the alignment and thread quality issues which led to a minor redesign of the box lug. We introduced a locking feature that minimized the gap and created a more secure fit. This can be seen on the box lug located on the right-hand side of the picture.
Second, Ultra addressed increasing production time by evaluating the tapping operation, which had previously been performed as a separate step after metal stamping. With the redesign of the box lug, this was the ideal opportunity to integrate the tapping operation into the metal stamping process, reducing handling and overall cycle time.
Install the locking feature in one new station.
Install the tapping operation in another new station.
This resulted in the metal stamping of 1,680 box lugs per hour on the press. After this production is completed, Ultra manages the heat treating and plating services for this metal part as well. The production process is completed at our facility with final inspection and packaging for delivery.
Customer Outcome
Production times and costs were reduced when the tapping operation was added to the new progressive stamping die.
The new locking feature improved the alignment of the part which allowed the inner threads to function as designed.
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