Increasing Production Rates & Precision Case Study

Customer
Recreational Vehicle Manufacturer
Part
Headlight Bracket

Manufacturing Issue

The (6) bends and (8) holes required a manufacturing process that produced no variance to achieve successful placement on the recreational vehicle.

Customer’s Goal

Locate a supplier that can provide an efficient and cost-saving process to produce the part with 100% accuracy AND meet production demands in a timely manner.

Manufacturing Process

This bracket could be formed with standard tooling in our Durma CNC Press Brake, but that brought up numerous issues:  an increase in costs and production times as well as a decrease in precision and consistency. Ultra's remedy was to utilize the capabilites of our in-house tooling department.    They custom designed and built THREE different tools to use in the press brake during the forming process. Each tool performed two bends at a time so that the bracket went through three stations for total completion versus six stations if using the standard tools. This customized tooling allowed for a more continuous production system and increased the production rate.

This manufacturing process in the press brake was much like a multi-station progressive die utilized in a stamping press; producing parts consistently and with greater precision. The customer couldn’t justify the cost of a progressive die based on quantities needed, but Ultra was able to deliver efficiency, precision and cost-savings using a press brake. This bracket also required laser work and Ultra utilized custom gauges to measure the positioning of each hole for correct placement.

Inserting grommets and pem nuts in the Value-Added Department.

Customer Outcome

Ultra’s use of customized tooling in the press brake TRIPLED the production output of this bracket.

Production with the standardized press brake tooling was 31 parts per hour and with Ultra’s customized tooling the output was 93 parts per hour.

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