Sustaining Production and Cosmetic Standards

The sheer length, 31 ½ inches, and weight, 54 pounds, were key factors in the customer selecting Ultra as the supplier of their ramp part. 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. And we designed this forming station to include five different operations to be performed in ONE single hit. The edges, top, sides, lips are being formed along with coining on the top of the ramp. This specific station is made of bronze material because it better protects the cosmetic integrity of the ramp. Another key component to this production was locating and maintaining material with protective coating to meet the customer’s cosmetic standards.

The edge quality of the ramp is of critical importance as it can easily be seen by the end user. A detailed process is followed to ensure smooth edges and cosmetic standards are attained.

  • Deburring of sharp edges.
  • Polishing of edges with hand sander.
  • Washing the ramp in hot, soapy water and drying with microfiber cloth.
  • Removing the protective coating for shipping and assembly.
 
  1. Ready for polishing and sanding
 
  1. Finishing the edges
 
  1. Smooth edges waiting to be cleaned
 
  1. Waiting to be shipped.

Other Case studies

Thrust Ring

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.

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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.

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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.

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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.

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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.

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