Customer
Motorcycle Manufacturer
Part
Fuel Filler Cup

Manufacturing Issue

  1. Production costs were increasing because a splash guard and (6) drainage slots were added to the part’s design to meet safety requirements.
  2. The part’s length changed with these newly added features and made the existing die unusable.

Customer’s Goal

Lower production costs for the fuel filler by utilizing a more efficient production process. Ensure the new features maintain the overall functionality of the fuel filler cup.

Redesign Process

It was determined that utilizing a progressive die to produce this part would cost less per part and require less labor than choosing to use a hand-fed option. A new progressive die was designed and built with numerous stations to produce the various features of this part. In fact, it required two separate stations to accurately form the threads into the cup. The six drainage slots were pierced from the inside to eliminate burrs and meet the customer’s cosmetic standards. With our 800- ton press and its 168” bed we were able to design this die to perform most of the operations during stamping, thus reducing time spent on secondary operations and significantly reducing part cost.

The final operation was the installation of the splash guard that was critical for safety purposes. Our smaller, hydraulic press accurately placed and secured the splash guard with very little labor required.

Customer Outcome

Ultra’s customized manufacturing process reduced costs as requested by the customer and even increased production rates. Our high-quality progressive die produced a fuel filler cup that matched the customer’s safety requirements. Appearance wasn’t overlooked during manufacturing and cosmetic standards were maintained.

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