Small Engine Metal Stamped Part Case Study

Engine Manufacturer

Governor Weight

Manufacturing Issue

The governor weight plays a critical role in an engine’s performance and the slightest deviation can lead to engine failure. The following issues needed to be fixed to maintain the engine’s reputation for quality and dependability.

  1. Inability to consistently attain the specified gram weight.
  2. Unable to get both legs in the correct position for exact fit and functionality in the engine.

Customer’s Goal

Ensure a defect free part within the set weight parameters at high levels of repeatability is produced and shipped.

Manufacturing Process

Material thickness was a key attribute to controlling the weight of the part.  We minimized the degree of natural variation that occurs during stamping by utilizing a tighter tolerance material.

The next challenge was determining a productive and cost-friendly method to verify the part’s weight was met and leg positioning was correct.  The ideal plan would allow for inspection of both criteria within one process.  Ultra’s hands-on manufacturing experience and technical expertise designed and built an innovative Governor Sort Machine for this automated inspection.  This machine can precisely and quickly inspect 1,000 governor weights per hour.

  • The governor weights were introduced into the inspection system through a large bowl feeder.  This process verified the two legs were positioned correctly by aligning the governor weights as they would be in the engine.  A part identified as a defect was kicked out immediately.
  • The governor weights then went through the weighing process.  One by one parts were placed in an enclosed area on a scale to be weighed.  At this point defective parts were kicked out or collected for final assembly.

Customer Outcome

Ultra’s Governor Sort Machine saved the customer time and money because inspection was reduced to one automated process.

The Governor Sort Machine is customized to work for only this customer’s part and eliminates downtime otherwise experienced when sharing equipment with others in a production setting.

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