Category Archive: Metal Stamping Cost Savings

Manor Tool Helps Support Engineering Education

The manufacturing industry has helped shape the face of our country for hundreds of years. With the development of new technologies, many professionals have been able to meet the growing application demands of the industry. As time progressed, applications became increasingly challenging, spurring the need for newer technology and competent workers to utilize said technology.

Manufacturing is widely considered a “traditional” industry, in which most of the professionals have decades of experience; though experience is a highly sought after trait, many workers have long since reached retirement age. With these workers retiring, the industry is looking for the next generation of engineers.

At Manor Tool, our team is all too familiar with this problem—that’s why we regularly participate in educational programs to encourage interest in manufacturing.

Last January, our company partnered with the University of Illinois to give students real world engineering experience. With support from Manor Tool, a senior engineering student team of four tackled some significant assignments. Students were tasked with:

  • Performing in-depth research on casting and other technologies that may be applicable for die fabrication

  • Selecting two dies and reviewing each for cost and lead time reduction

  • Analyzing current stamping drawing designs, materials, and applications

  • Researching lubricant technologies for the materials selected

  • Analyzing force and friction environments in which the dies much withstand during stamping operations

  • Development of progressive die fabrication and lubrication alternatives for die design

  • Reviewing alternatives with Manor Tool personnel for applicability, feasibility, cost, potential prototyping, testing and economic analysis

  • Finalizing recommended designs, lubricants, and economic analysis for delivery to Manor Tool & Manufacturing Co. along with final report and presentation

 University of Illinois and Manor Tool  Back Row left to right: Pratham Gandhi, Brian Hoppe, Matthew Wiencek, Jingtin Lin. Front Row left to right:  Kevin Segebarth, Tom Simeone

  

Our engineers provided students with feedback for each of these tasks and helped finalize the results for highly detailed reports and presentations. Each team of students worked diligently to complete assignments under the watchful eye of Manor Tool’s team of specialists.  

“It was great seeing the students’ progression over those few months, said Kevin Segebarth, General Manager of Manor Tool. “I was impressed by their very professional manner and eagerness to learn—in my experience, many engineers don’t fully recognize the importance of continuing to learn and grow.”

Learn more about how Manor Tool supports the next generation of engineers by contacting us today.

 

Would You Like to Cut Down on Metal Stamping Costs?

There are many facets of your company to consider when you want to cut costs. One way to go is to schedule a meeting with one of our skilled design and manufacturing engineers here at Manor Tool to review your drawings and production plan, and help your company meet low or high volume production requirements. Whether this is your first component or your 1,000,000th, Manor Tool can help you cut costs and save money with a “second set of eyes.”  

Offline Time?

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For example, how often are your current dies taken offline for repair and re-tooling? If your current design requires frequent offline time for die repair, have you been able to determine the features that are causing this down time and the lead time extension? Review your design to determine the possibility of altering these features to simplify the component and eliminate unnecessary wear on your die and tooling. Manor’s engineering staff can aid your team with this issue.   

Tooling?

As far as tooling goes, review your current requirements for your components and determine if there are alterations that can be made to reduce complexity and maintain functionality. Just changing square holes to circular holes drastically simplifies machining and tooling requirements. This will reduce your production time and your overall component cost. What about your design and the number of machines and processes that are required? Can changes be made to utilize the same machinery or process?

Automation Possibilities?

Are there portions of your design that currently require manual intervention? You should probably go over these areas to identify possible automation or elimination. Manual machining operations are costly and time consuming. Anything you can do to reduce this will have an immediate impact on your component cost. Our engineering team can help identify opportunities to automate feature creation for your parts.

Having an expert third party review your design and provide feedback is just one of the tips we at Manor Tool can offer you. If you’re interested in a few more tips, Manor Tool has put together The Cost Saving Guide to Metal Stamped Parts which gives you 23 tips that will help save on your next metal stamping project.

To download the eBook Guide, click the button below, or contact Manor today and let us assist you.

  Looking to cut down on cost?Download our Metal Stamping Cost Savings Guide

Manor is Punching Up Production with Acquisition of Turret Press

Manor’s metal stamping and deep draw services encompass a wide range of metals. And since we offer custom tooling and fabricating services for such a diverse array of customers, all in need of specific requirements, we are always on the lookout for the latest machinery to help us serve customers’ needs the best way possible.  In modern, flexible manufacturing, jobs vary, and so should machine tools.

November’s blog mentioned “Freddy” – our robotic work cell that has proven to drastically reduce cycle times for a number of clients. It’s certainly been an innovative use of automation for metal stamping at Manor. Now we’ve added a high-tech press to our arsenal of equipment: a new turret press from Finn-Power, the twenty-year pioneer in hydraulic turret punch presses.

Our new C5 Express Press is a unique combination of reliability, versatility and high performance, as well as ease of operation and maintenance. As a lower cost option for initial low-volume, development volume, or prototyping, the new press offers customers the ability to develop parts before investing in hard tooling for large volume runs.

Manor’s new Finn-Power C5 Express features an auto loader, robotic pick up sheets and loads, and remote programming, all designed to increase production time. Fully networked, the machine allows engineers to develop processes from drawings, using sophisticated NC Express Cam software that generates the G-code for tool paths that are sent to the machine for manufacturing.

The new press adds full networking capabilities, faster processes, lower noise levels, more energy efficiency, and a safer operation. The Finn-Power C5 Express features 20 main tool stations and three multi-tool stations, utilizing one station with 24 tools up to ½” in diameter, and two 6-tool stations with up to ¾” diameter. The result is 53 total tool stations, and a maximum punch diameter of 3.5”.

Additional features include multiple tool-holder sizes that can be switched from station to station, the option for additional index stations, multiple shaping capabilities, multiple job runs from one setup, and an automatic built-in scrap conveyor for fast scrap removal. The machine also offers fast loading and unloading with a smaller footprint.

Manor notes that this new press will allow for immediate tool availability in a short amount of time. The new press, along with Manor’s relationship with suppliers, allows them to have tools delivered to clients within two days.

Two days:  That’s good news for company and clients alike. 

Learn how tools like our new Turret Press allow us to help customers reduce the cost of Metal Stamped parts in our eBook:

Looking to cut down on cost?Download our Metal Stamping Cost Savings Guide

Ford’s Advanced Prototyping: The Future of Metal Stamping

A long time ago, blacksmiths performed the most basic metal stamping with blows of a hammer. Since then, metal stamping has grown infinitely more advanced. Stamping is a truly integral part of the production process today, and plays a large role in a number of industries. Innovation in technology and automation has improved the metal stamping process in exciting leaps and bounds. One of those innovations is Ford’s advanced prototyping.

In the past, it took between 6-8 weeks for Ford to produce a die to stamp a part for a prototype. Thanks to their revolutionary new system, however, that process now only takes mere hours.

Klein1In this process, Ford’s designers create three-dimensional CAD drawings which are then sent to a machine that uses a pair of robotic arms to bend and weld the material into shape. The arms bend and shape a piece of two-dimensional sheet metal into a three-dimensional object, creating a one-off part in as little as a few hours. It’s a truly advanced manufacturing process that has never been done before.

While the process is—by industry standards—lightning fast, it has been years in the making. The engineers at Ford had a vision and a goal of what could be done, and progressed toward that goal over the years using innovation and advanced technology. After significant research and testing, it became what it is today—a perfect example of the current state of American manufacturing.

This technology only exists at Ford right now, and the possibility of using it for mass production is still years away. Yet it has a number of implications it has for the future. Ford’s advanced prototyping has paved the way for other applications and industries, creating true potential for metal stamping down the line. We can’t wait to see what kind of changes this new technology will bring to the industry.

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A Guide to Reducing the Cost of Metal Stamped Parts

In this day in age, it can be challenging for companies to save money on a day to day basis when there is a need to purchase materials and equipment. There are 10 easy ways in order to save your company some money when dealing with the costs of metal stamped parts.

describe the imageMetal Prices: With current fluctuation of metal prices, you may be able to find savings in an alternative material that you did not consider previously. For example, frequently we are able to substitute 1050 Annealed Spring Steel for HSLA with minor design modifications.

Tooling Requirements: Review your current tooling requirements for your components and determine if there are alterations that can be made to reduce complexity and maintain functionality. For example, changing square holes to circular holes drastically simplifies machining and tooling requirements. This will reduce your production time and your overall component cost.

Product Design: By analyzing the current design performance you may be able to identify areas of design modification that can reduce your costs. You may be able to alter your design slightly to provide advantages in other areas while maintaining the function and integrity of the part. Some changes would allow you to ship more parts together and deliver more parts in each shipment.

Services: If your component currently requires services from multiple vendors, investigate finding a partner that can supply all of these services for you. Not only will you save on shipping costs, but you will have one point of contact for the successful production of your component.

Production Volume: Has your production volume increased without reviewing your original design? Frequently the need for more components is met with a basic increase in production orders. When volume increases the opportunity arises to streamline your product design to increase manufacturability and production timelines. If you are still using your basic prototype design, now is the time to analyze where changes can be made to still achieve the required functionality from the component, while reducing costs.

untitled2Layouts: By changing the layout of your components you can produce more pieces using less material. If your original layout had 10 parts on your design and you can fit just one more, you are now getting 10% more products for the same material price!

Delivery Scheduling: Consider how alternative delivery schedules or carriers may impact your profitability for each component

Company Partner: Make sure your current metal stamping partner has a deep understanding of your area of expertise. Frequently different vertical markets will require different production steps or documentation.

Project Management: Review the project information and feedback you are provided for reliability, expediency, quality and accuracy. If you do not have strong project management for your metal stamping components, you will lose time managing the project yourself.

Alternate Machinery: It is possible that different machinery may allow you to condense your production runs by combining feature creation. By reducing the number of passes, tooling setups/fixtures, and manual machining the cost of your component can decrease.

By keeping in mind these 10 quick and easy steps, you will be surprised at how much money your company will end up saving. 

 

Looking to cut down on cost?Download our Metal Stamping Cost Savings Guide

 

 

Finite Element Analysis (FEA) Offers Problem-Free Production In Component Manufacturing

In component manufacturing and metal stamping, sometimes there are complex geometries in projects, and these complexities offer an infinite number of variables that could negatively impact quality control. For most component manufacturing or metal stamping projects, it makes sense to take advantage of the benefits of performing a Finite Element Analysis (FEA) to ensure problem-free production and positive end results. FEA offers you peace-of-mind by ensuring that your designed component can be manufactured at a production basis, at a point where you can make adjustments, if necessary.

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At Manor Tool & Manufacturing, we’re experienced at conducting FEA, and, with our clients, we’ve witnessed the benefits of FEA first-hand.

Here’s how FEA works: Using FEA software, we turn your product design geometry (the final part design) into tooling surfaces and use it in simulation to engineer a successful forming process in the “virtual world” – at a place and a point where design imperfections can be caught and fixed without negatively impacting tooling, production or your business’ bottom line.

Through our extensive engineering experience and FEA capabilities, Manor offers our clients the know-how and assistance required to help them decrease production costs, save time on their projects, and deliver problem-free production, no matter how complex the design specs might be.

On your next component assembly project, we can help you achieve these benefits – and give you confidence in the final results.

Work with Manor to get innovative component manufacturing solutions that deliver efficient, cost-effective, progressive die-stamped products. Contact us to learn more about our capabilities and to discuss Finite Element Analysis in more detail. Or visit our portfolio gallery and read one of our customer’s success stories using FEA to maximize the effectiveness of the die-stamping process. We look forward to working with you!

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