Page 24 - MetalForming May 2011

Stamping Stainless
Multifunctional Grinding
and Polishing System
• Ideal for flat surfaces and open or closed pipe constructions
• Grind from a coarse to shadow-free brush finish, up to a
mirror polish
• Remove welds, deep scratches, oxidation, rust and paint
PIPE-MAX Pipe Belt Sander
• Polish stainless and all metals
• For sanding handrails and
pipes up to 12”
• Grinds weld seams on flat surfaces
Slip-on Abrasives!
PTX Eco Smart Kits
Grind In Corners!
Beveling & Deburring Solutions
Beveling & Deburring Solutions
Ideal for Stainless Steel, Aluminum and More Sheet with burr after cutting
Rolei® BE5
Double-sided Deburring of Sheet Metal up to .2" Thick
• Simple, one-step deburring
• 2 speeds: 600 and 1200 RPM • 220 V or 440 V, 3-phase
Deburring on both sides of the sheet edges
Bevel, Deburr & Chamfer
• Adjustable beveling angle from 30˚ to 60˚
• Hand-held and table-top units for small
and large applications
• Bevel 15˚ to 60˚ angles on plate or pipes
• Fast, easy preparation of weld seams
Visit csunitec.com for our full line of metalworking tools, and to view demo videos.
Surface Finishing Solutions
1-800-700-5919 • www.csunitec.com
Results from the overall project have been impressive. First, the plant gained control of the process. Says Sprouse: “Schedule changes are easily accom- modated. Also, scrap and rework rates are down considerably—scrap is a mere 3 cents/unit manufactured, half what it was previously, thanks to the dedication of our crews to keep the dies clean. Reject rate from the press is less than one percent, and through the entire system (including debur- ring, coating etc.) scrap rate is less than two percent.”
Less Deburring Contributes to Lightning-Quick ROI
Another benefit realized from gain- ing process control inhouse: Only about half of the parts actually require deburring, whereas all stampings were undergoing the secondary process pre- viously. What no longer needs debur- ring? Those stampings that undergo a special Electrolux-developed anti-fin- gerprint stainless-steel coating process, thick enough to cover any burrs typi- cally produced.
“We used to pay for deburring of every part stamped by our supplier,” says Carr, noting that acceptable burrs off the press are 0.004 in. or smaller. Larger burrs create problems for the company’s subcontracted deburring house. “Not only are we saving time and money thanks to less deburring, but we eliminate one more opportuni- ty to have the surface finish of the parts marred,” Carr adds.
When accounting for all of the ben- efits, the stainless-steel stamping proj- ect allowed Carr to realize a substan- tial improvement in PPV and overcome a company-wide freeze on capital spending. “Our case was simply too good,” she says. Using a modest run rate of 50 units/hr. (compared to the actual run rate of 300/hr.), Carr and the plant’s production team were able to show a 9-month return on investment for the project.
“The presses are performing, the dies are performing, and the people are performing,” says Frauendienst.
MF
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22 MetalForming/May 2011
www.metalformingmagazine.com