We custom design, manufacture, test run, and commission machinery for mass production of auto parts The unique advantage to our customers is that we are both, mass producers of the parts, and manufacturers of production lines to mass produce them. In fact, in all cases so far, we have been our first customer. As you will read in the following case studies and white paper we have, in the last few years, designed and produced systems for mass production that are up to 500% more efficient in production costs compared to the conventional systems, both in the number of operators and the output capacity.
This simply means that the direct production cost of parts drops by up to 5 times.
Brake Caliper Variable Pitch Transfer Line
The following is our latest and most efficient transfer line production system.
In 2013 we were awarded a contract to redesign /upgrade a conventional CNC based Brake Caliper production line. The customer wanted more efficiency, less labor intensive, higher quality with the minimum capital investment. The final redesigned system was a variable pitch transfer line with the following summery comparison to what it replaced.
• Production increased 6 folds to 10,000 parts per day.
• Direct labor reduced five folds, to 20 persons per day.
• Maintenance cost reduced 5 times over 3 years.
• Internal machinery PPM reduced 70% to 300ppm
All these benefits, with an initial investment cost which was recouped in less than 1.5 years. Customer was thrilled.
As you can see from the schematic, design of the brake caliper system includes 32 operations with a cycle time of 50 second, from the first to the last OP. Each OP takes 6 individual parts, (3 calipers, and 3 brackets) placed in the appropriate Transfer Pallet. One pallet takes in the correct parts for the right wheel set, and the other takes the parts for the left well set. Transfer pallets are identified as they enter each OP. If necessary, there is the flexibility of feeding more of right set pallet or the left to balance the production rate.
Clamped only once in the pallet, parts move though all OPs, eliminating possible displacement problems and therefore reducing system PPM.
The system design gives access to five sides of the parts in the pallets, reducing number of OPs and associated machineries and the overall cost.
The variable pitch transfer line system designed by our engineering group allows farther cost reduction by minimizing the required real state.