CNC SWISS MACHINING CASE STUDY: Automobile 11 Degree Connector Project
Our CNC Swiss machining case study involved an automotive components company who was seeking a manufacturer to make a product that could be machined as one complete part and in one operation. At the time the part was manufactured in the following five operations:
- Turning blank of part
- Two secondary milling operations (milling flats and milling 11-degree diameter on the face of the part)
- Two brazing operations of the two components before final assembly
After collaborating with our customer’s engineers, we devised a two-part operation process to develop and prototype one part while eliminating conventional secondary machining. New process:
- Developed a unique milling holder held at an 11 degree angle
- Utilized a form tool to mill the diameter on the face of the part
- Cost- By eliminating secondary machining, the new cost was reduced by 39%.
- Time – Original cycle time on the part was 8 minutes 23 seconds per piece. Together with the new changes and engineering support of our customer, the cycle time was reduced to 3 minutes 10 seconds per piece.
- Savings – The direct savings over the course of this project was $362,790.
|Cost||Saved 39% per part|
|Time Savings||Reduced to 3 min. 10 sec. (62% reduction)|
|Overall Part Dimension||.600" Length, .866" Diameter|
|Overall Tolerance of Part||+/- .0004"|
|Material||7/8 304 Stainless Steel ROHS/Defars Compliant|
|Industry||Automotive (Fuel Rail Systems)|
|In-process Inspection||Ram Optical, Micrometers, Deltronic Gage Pins,Thread Gages|
|Manufacturing Specifications||Per Customer Drawing|
|Original Cycle Time||8 Minutes 23 Seconds|
|Improved Cycle Time||3 Minutes 10 Seconds|
|Original Lead Time||6-8 Weeks|
|Current Lead Time||3-4 Weeks|