Other Case studies
Collaborative sessions with the customer helped Ultra fully understand the functionality and features of the thrust ring and established a productive setting for die designing and building. It was identified that the part’s tabs required a tight tolerance of no more than .062” to achieve correct alignment with threads during the multi-assembly process.
Fuel Filler Cup
Production costs were increasing because a splash guard and (6) drainage slots were added to the part’s design to meet safety requirements. The part’s length changed with these newly added features and made the existing die unusable.
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.
Outdoor Power Equipment Manufacturer
Manufacturer of Rotary Lawn Mower Blade Sharpeners and Balancers for the Outdoor Power Equipment Industry
A recommendation from their previous supplier brought Outdoor Power Equipment Manufacturer’s leaders, Gerd & Erik Bauer, to Ultra’s front doors to continue production of their lawn mower blade sharpener.
Honda Power Equipment
Tabs on a lock washer were not forming correctly, causing continuous frustration and part assembly delays. The tabs needed to be redesigned to deliver the correct force and maintain the washer’s locking feature.
Rockwell Box Lug
A box lug was both mis-performing and slow to produce. A collaborative redesign introduced a new locking feature, correcting thread alignment and improving overall part quality. Plus a switch to a progressive die combined a number of operations into a single, fast production process.