400 ton Minster in production of complex drawn part


Ultra Tool’s people are toolmakers and we know that quality starts with reliable tooling. From our owner and managers to our designers and master toolmakers, we’re all exposed to the production environment every day, so you can be assured that we have the experience and skill to build high-quality tools.

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Case Study - Harley Davidson

CLIENT:  Harley DavidsonHarley Davidson

PROJECT:  Transfer of Top Plate part from old supplier to Ultra

DATES:  June 2009 – Jan 2010

Challenge:  Renowned motorcycle manufacturer, Harley Davidson, relies on the stability and efficiency of their suppliers to keep production lines running. When the supplier of their Top Plate Assembly went out of business, leaving them with a diminishing inventory bank, they were in need of a new, qualified supplier that could transfer the part’s production quickly and smoothly. With three different assemblies, each one comprised of six components and five operations, the swift transfer of the part was no small task.   
Execution:  The clock was ticking when Ultra Tool and Manufacturing was awarded the job. Although production couldn’t start until the equipment arrived, communication and planning in the meantime were essential. A project manager was assigned to the project as a direct point of contact with the customer. In turn, the manager assembled a cross-departmental team that met daily to asses the part’s current production process and to create a timeline of activities necessary to meet the short lead time.  

Open lines of communication both in-house and with the customer allowed the team to address problems quickly before production started. When the tools and materials arrived, Ultra Tool had 6 weeks to modify and improve the tooling and to get them running in the press and producing parts to print.  

Result:  This assembly has multiple purchase and stamped components. The tube is brazed in-house.Through their detailed and regimented approach, Ultra Tool beat their own timeline projections by delivering all three assemblies a week or more ahead of schedule.  In addition, their careful analysis of the production process allowed them to manufacture a higher quality part at a lower price.