Case 1
Combining two parts into one by dual transfer machining greatly reduce cost and improve productivity!
Client: Top Japanese Canner
Two parts were formerly joined together to produce a very special can.
This method leaves little room for further cost reduction to combat ever fiercer competition.
The client asked us to come up with a new innovative approach to form a can in one step.
Unexpected Visit
A canner together with their press manufacturer called on us without notice. Their task was an extremely difficult drawing venture. Through discussions on their objectives and entailing barriers, we proposed workable solutions. We eventually formed a joint project to work out a new die and press system.
The staff from the canner was extremely enthusiastic in the project, under his leadership; we formed a team of machine manufacturers, press manufacturer, and our own five staff members.
First step was to perform an extremely deep reverse redrawing to unify two parts. This step was cleared by incorporating special devices into their stamping machines.
We slept just in front of press machine.
The next obstacle was to mix a suitable lubricant. The can was for preserving food; therefore, industrial lubricant could not be used. A very limited amount of specific lubricant for food can was allowed in this operation.
We took following four measures to clear the hurdles.
- Introduced cooling water to upper and lower dies to prevent scuffing (scars) caused by heat.
- Prevented material scraps attached to the die from persistently scarring the work piece and other parts.
- Utilized material as soft as possible.
- Set the clearance wider and made the slide hollow.
In a hot mid summer month, continuous effort was made into an awkward situation. Our team started to stay at the client's dormitory. From time to time, we worked late and slept on the work-floor laying out rugs in front of the press machine. Finally, we came up with an ideal combination of material and clearance.
At the same time, we ventured on improving the production line. After a series of trials and errors, we could double the productivity by incorporating two sets of transfer devices to one press machine.
We spent five months to design, make and assemble dies, further six months were spent to reach flawless, continuous operation.
All drank a toast to the success!
With reverse redrawing, newly compounded lubricant and dual transfer system, we could complete a new canning system which could beat any competition on the market. The new fully automated production line was comprised of press machine, trimmer, air checking device, labeling, auto-feeder and packing machine. The hundred meter production line quadrupled productivity and reduced the cost in half.
Applauds continued for a long time at the completion of the production line. Japanese wine was poured onto the machine and every member happily drank a toast to celebrate the occasion.
This is a glorious achievement by the team under the leadership of the client and the assiduous guidance of WISMA.
This is the beginning of our current partnership arrangement between the client and WISMA based on our high technological expertise and mutual trust.
