Maintaining efficiency and low costs for high volumes

This customer's production needs are 600,000 – 700,00 pieces per year for FIVE different parts. These parts have a uniform shape with slight variations in each design. Parts A and B shown here are almost identical except for the design and dimensions of their bottom lips. The previous supplier was utilizing secondary machining to crimp the lip after the stamping process and this method was expensive and extended the production time.

Ultra’s first improvement was to remove the crimping operation and replace with coining in a progressive die. The customer was reluctant of this modification and with prototyping we successfully proved this manufacturing method delivered the parts as designed.

Ultra’s second improvement was to reduce their capital costs for tooling by consolidating their progressive dies from FIVE to TWO. This was feasible due to the uniform shape and design of the main component for their parts. One progressive die was designed to stamp three separate parts that were grouped together because of a similar design and features; and the other progressive die was designed to stamp the remaining two parts with similar designs and features. The key to these dies was the last station. It was designed and built for easy changeover to one of five different custom stations to finish the stamping process.

These improvements delivered cost-savings in two key areas.

  1. Eliminating secondary machining and then providing that operation in the progressive dies.
  2. Utilizing only two progressive dies eliminates maintenance and labor costs.

Other Case studies

Sustaining production and cosmetic standards

Our 800-ton stamping press combined with our secondary, high-quality services proved Ultra could completely handle the ramp’s production all at ONE facility.
The ramp is manufactured on a progressive die that includes only ONE forming station to complete that stage of production.

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Die Maintenance

This was leading to a decline in the precision and quality of work being performed. Concern was growing that this inconsistent service would negatively impact the quality of their products.
The customer’s plan of action was to establish a tool & die shop that could successfully handle the quantity and diversity of their dies for regular preventative maintenance and unexpected service issues.
Ultra was able to deliver a customized service plan to fit the needs of the customer.

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Improved Efficiency

This customer needed a different design intent for the filter cutting component of a die utilized in an existing assembly machine.  The current design was causing cutting and maintenance issues; leading to a decrease in the quality and consistency of their final product. Our design team reengineered this die and the cutting component with a […]

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Customizing Components

This customized, low-volume project successfully merged the technology of our fiber laser cutter with the hands-on work of the cut-off saw. Ultra manufactured six different components for the customer with specific measurements and established for each.  The component pieces consisted of either a base plate or a tube. The three different base plates were cut […]

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Producing precise and cohesive parts

The most critical feature in laser cutting the disks was the slots. Their placement needed to be exact along with a tight tolerance to ensure correct alignment with the blade’s tabs. Our quality system establishes the programming of the laser is correct with a set-up check; and then in-process checks…

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