Summary
A Chemical Pumps Company in NE Indiana faced delivery and quality issues with their previous supplier. Toolcraft stepped in with a Robotic Machining Cell and two Okuma Lathes, ramping up production to 700-800 parts in a 10-hour shift. By incorporating quality checks, including an Initial PPAP, Toolcraft ensured the delivery of high-quality flanged inlets, meeting the company’s demands.
Project Overview
- Industry: Chemical Pump Manufacturing
- Process: Lathing, Machining, Quality Inspection
- Category: Contract Manufacturing
In NE Indiana, a Chemical Pumps Company was grappling with supply challenges. Their previous supplier had issues delivering the required flanged inlets, and the quality was lacking. These inlets, crucial to the company’s pumps, had specific requirements, and the company was under pressure.
Toolcraft, LLC, recognized the urgency and provided a practical solution. They implemented a Robotic Machining Cell that efficiently handled castings for two Okuma Lathes. These lathes, equipped with a sub-spindle and live tooling, allowed for a smooth production process. With this setup, Toolcraft could produce around 700-800 parts during a 10-hour shift, comfortably exceeding the company’s daily requirement of 650 pieces.
Uses and Applications
- Chemical pumps
- Fluid transfer systems
- Industrial processes involving fluid handling
Capacity
- Production rate: 700-800 parts per 10-hour shift
- Machine capacity: Two Okuma Lathes with sub-spindle and live tooling
Quality Control
- Initial PPAP (Production Part Approval Process)
- Regular hard gage checks
- Dimensional inspection
- Material analysis
- Visual inspection
- Functional testing
Quality Control
Toolcraft’s comprehensive quality control procedures ensured the Brass Die scraper met stringent performance and reliability standards:
- Dimensional Inspection: Coordinate Measuring Machines (CMM) were used to verify all critical dimensions and tolerances.
- Material Testing: Metallurgical tests were conducted to confirm the material’s properties and compliance with specifications.
- Non-Destructive Testing (NDT): Techniques such as ultrasonic testing and magnetic particle inspection were employed to detect any internal or surface defects.
- Functional Testing: The assembled Brass Die scraper underwent rigorous functional tests to ensure proper operation and integration with Michelin’s manufacturing process.
- Final Inspection: A thorough final inspection was performed to validate the overall quality and readiness of the Brass Die Scraper before delivery to Michelin.
Manufacturing Process
Raw material procurement
Sourcing of appropriate metal castings.
Machining
Robotic cell handling of castings, Turning and machining on Okuma lathes using sub-spindle and live tooling, Creation of flanges and other features.
Quality inspection
Hard gage checks for dimensional accuracy. Visual inspection for defects. Other relevant inspections as per specifications.
Finishing
Surface treatment
Assembly
Integration of flanged inlets into pumps.
Packaging and shipping
Proper packaging to prevent damage during transportation.
Conclusion
Ensuring the quality wasn’t compromised, an Initial PPAP was conducted, and the production process incorporated regular hard gage checks. This combination of efficiency and quality control meant that the Chemical Pumps Company now had a reliable source that met both their quantity and quality expectations.