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The Z-Carb HTA Produced 4 Times as many Parts Per New Tool as the Competitor’s Tool in 4140 35-40R/C.

4/1/2019

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GOALS
The goals of this study were to
significantly reduce job cost through increasing tool life and maximizing operating efficiencies
STRATEGY
The Z
-Carb HTA features an enhanced high helix design and enhanced core to meet the demands of machining high-temperature alloys.

The patented unequal helix design
changes the angle at which each cutting edge enters the material, and unequal flute spacing helps disrupt the rhythmic pattern created by the cutting edge.
Picture
The Z-CARB HTA. Designed for High Temp Alloys
Z Carb High Temp Alloy Test Results
In this case, the Z-Carb HTA outperformed the competition by every single statistical measure.
The HTA was a
ble to handle a 12% increase in speed.
Easily took
on a feed rate double what the competitor’s tool could handle.

With th
ese increased efficiencies, the material removal rate was doubled!
RESULTS

Thequality of tool and the substrate coating played a role in increasing the tool life.

The customer needed to produce 5,000 parts and because the HTA produced 4 times as many parts per new tool as the competition, it only required 42 total new tools to complete the job. The competitor had to use 167.

The
customer, because of the smaller amount of HTA’s needed saved over $13,000 in new tool cost.

When you combine that number with the over $
14,000 saved in machining cost (because of the increased efficiency mentioned earlier) the customer saved a grand total of $28,153.70!
Picture
Z Carb HTA Performance 35 40 Rc
Z Carb HTA Performance 35-40 Rc
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Case Study: Toronto Mold & Die Shop Cuts Set-up Time by 90% with Modular, Quick Change Workholding

5/16/2018

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Mold & Die Shop Cuts Set-up Time by 90%
With forty years under their belt, 120 employees, multiple customers with different machining and material demands, and a successful business, the shop turned to Jergens in 2015 to explore options for a better way. A better way to hold the large variety of components that the shop had grown to manufacture for its customers in the mold and die industry. They did, and they did it so well it earned them a reputation in the industry as ‘the aluminum experts’.

The Workholding Challenge

The shop had to build and maintain over 150 different custom fixtures of widely varying configurations. Furthermore, products produced spanned eight different categories, required expertise in CAD, engineering, prototype parts, machining operations including five axis, tooling and the list goes on.

In addition to ordering a range of steel sub plates, fixture plates and numerous clamping components to make the fixtures, the shop also had to machine and assemble them. So, before a single chip hit the floor from a customer part, they had to make their own set ups. They did well, obviously they are a skilled shop, but realized that a better solution had to exist.

Jergens Workholding Solution

By choosing Jergens, and their Zero Point System (ZPS), the shop was able to accomplish three things immediately: refocus on their core business as an expert manufacturer of components within the mold and die industry, secondly, implement a far superior system and lastly, achieve tremendous cost savings.

The ZPS mounting system is a real game-changer for the industry and provides two key advantages – speed and repeatability, less than 0.005mm (0.0002”). The speed part of that equation is that, with ZPS, users can fix, position and clamp all in one step, saving set up time in many cases by as much as 90%.

There are many options within the ZPS including units that feature either pneumatic, hydraulic and manual actuation. A newer style even features a clamping module with sensors to provide clamping force feedback. A range of clamping pla
Jergens ZPS Zero Point Workholding

The Results

For the shop, the biggest realization (economic impact) came from the analysis of the true cost to manufacture and assemble the fixtures, and the incredible reigning-in of set up time – 90% reduction.

Prior to the Jergens ZPS solution, the time it took for each set up was ten minutes, and there was an average of thirty setups – that’s five hours per day spent just in setup time. That average time with the change to ZPS went to just one minute, or one-half hour total per day.

At a rate of $100 per hour, that’s $450 per day in savings, or $112,500 annually!

Tom Reid, Canadian Sales manager for Jergens, who works very closely with the shop, reported, “I’ve seen a lot of positive results, particularly with Drop and Lock (another popular quick-change pallet option) and ZPS, but don’t recall one as dramatic as this in recent years”. Tom continued, “We work closely with the customer to engineer and provide these solutions, and also measure important calculations such as ROI, which in this case was about five weeks”.

The end result for part production was significant and predictable - error reduction, reduced scrap, easy part orientation, and better / more consistent output from the manufacturing floor.

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