The Ultra Report, Winter 2008 - In-Die Automation, Metal Stamping, Tool and Die

In This Issue

Significant Savings with
In-Die Automation
NEW Case Studies-
• In-Die Assembly (PDF)
• In-Die Measurement (PDF)
• In-Die Welding (PDF)

Read All the Details!

New! Ultra Tool's
Success Model <Go>

Inside Ultra Tool
• BotsIQ
• PBS Airs Mfg. Segment
• Upcoming Trade Shows
<Go>

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Significant SAVINGS with In-Die Automation
The Challenge
   So many times an assembly or part gets quoted with unnecessary secondary operations adding to the cost of a job. These can be avoided utilizing in-die processes developed for our customers at Ultra Tool & Manufacturing.

Three PROVEN Solutions
   Ultra Tool has successfully run dies with advanced in-die assembly, in-die measurement, and in-die welding processes. Our case studies prove that we not only believe in the latest in-die technology, we prove it through detailing a job every step of the way.
    We've put together case studies that detail quantities, material, press speeds, etc and above all, cost savings. <Continue for Details >

Introducing — The Product Development
Success Model
Communication is critical
to every part of a project.
The ability to listen to a customer's needs and apply the most innovative and cost-effective solutions is what we do everyday.

A TEAM Approach
   At Ultra Tool, we use a team approach consisting of estimating, quality, and tooling engineers working together to fully understand a project from start to finish. Developed by Ultra Tool, the Success Model (pictured) shows four stages built around the ongoing success of your project: plan, design, execute and improve.
   PLAN — Our planning tools include: a project scope to determine the needs of your project, an accurate and timely quote, and after receipt of the job we chart the project through our New Product Introduction process (NPI).
   DESIGN — The design process begins with an experienced team of engineers and die designers offering only the most reliable, robust designs built to ensure quality and repeatability of your part.
   EXECUTE — Mistake-proof manufacturing and an in-house sensor program make us a leader in advanced manufacturing technologies. Our core strengths lie in metal stamping and tool building.
   IMPROVE — Technology will be the forefront of our growth in the upcoming years. Our priority is customer satisfaction through the advancement of technology that will increase efficiences, improve quality and in turn, lower costs.

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Inside Ultra Tool

Bring on the Battle!
   Recently, Ultra Tool & Manufacturing had the privilege to help out a local high school team involved in an exciting educational contest known as BotsIQ.
What it is
   BotsIQ is an educational program promoting math, science and engineering expertise, along with competitive sportsmanship and creativity. These skills are then put to the test through the design and creation of competitive robots. One dozen students from Kettle Moraine Lutheran High School met twice weekly, using AutoCAD to complete their design.
How we helped
   With a little help from Ultra Tool enthusiasts, the students built a great robot with hardware and materials donated by Ultra Tool & Manufacturing. The robot's look was completed with a suit of armor – a carbon fiber shell, donated by Trek Bicycle. The students plan on taking "Death Mellon" on the road for local competitions around the state.

PBS Airs Segment Featuring Midwest Manufacturing
   The segment from “The NewsHour with Jim Lehrer” was the second of a series of reports on America 's response to globalization and how U.S. manufacturers are fighting to close the cost gap with global competition.
   As a metalforming supplier for Harley-Davidson, Ultra Tool and Manufacturing demonstrated how they compete globally by designing products that reduce material costs and eliminate waste. As shown in the report, a re-engineered part for Harley-Davidson eliminated costly secondary operations and reduced material costs by going from a three-piece assembly down to one.
   Simulation software was also demonstrated as a successful tool in the reduction of labor costs by boosting productivity.
   Streaming video is available online on the PBS web site link:
<The NewsHour with Jim Lehrer>

Upcoming Trade Shows
   Regional MetalForm Show, Birmingham, AL (Booth #718)
     April 1-3, 2008 www.metalform.com
   SAE World Congress, Detroit, MI (Booth #0718)
     April14-17, 2008 www.sae.org/congress
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