CASE STUDIES
Transmission Case
Scope: (9) 50-Sensor Systems
Die: 4-Slide
DCM: 3,000T
Improvements:
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Eliminated (3) Dual Zone Hot Oil TCUs
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Reduced Spray Volume 74%
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Reduced Cycle Time 42%
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Expanded Capacity Vol w/o Capital
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Reduced Metal Temp & Shot Weight
Before:
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External Scrap: 2%
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Energy: 3 x 480V 80A
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Spray: 1.75 gal/cycle
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Cycle Time: 165 sec/cycle
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Metal Temp: 1,230°F
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Biscuit Th: 2.5"
After:
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External Scrap: 1%
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Energy: 1 x 120V 5A
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Spray: 0.45 gal/cycle
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Cycle Time: 105 sec/cycle
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Metal Temp: 1,210°F
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Biscuit Th: 2.0"
Clutch Housing (3-Cavity)
Scope: (1) 30-Sensor Systems
Die: 4-Plate, 3-Cavity
DCM: 1,800T
Improvements:
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Productivity Improvement Eliminated 2nd DCM and Weekend O/T
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Reduced Spray Volume 37%
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Reduced Cycle Time 41%
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Eliminated (1) TCU
Before:
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External Scrap: 2%
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Energy: 2 TCUs
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Spray: 1 gal/cycle
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Cycle Time: 128 sec/cycle
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Metal Temp: 1,240°F
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Biscuit Th: 2.5"
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Capacity: >1 DCM
After:
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External Scrap: 1%
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Energy: 1 TCU
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Spray: 0.63 gal/cycle
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Cycle Time: 74 sec/cycle
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Metal Temp: 1,200°F
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Biscuit Th: 2.0"
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Capacity: 1 DCM
Structural - Torque Box
Scope: (1) 67-Sensor Systems
Die: 1-Cavity
DCM: 2,700T
Improvements:
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Productivity Improvement Eliminated 2nd DCM. Allowed capacity for new program
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Reduced Cycle Time 49%
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TCUs Reduced 56%
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Reduced Solder Polishing Frequency
Before:
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Energy: 9 TCUs
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Cycle Time: 109 sec/cycle
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Capacity: >1 DCM
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Biscuit Th: 1.5"
After:
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Energy: 4 TCU
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Cycle Time: 56 sec/cycle
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Capacity: 1 DCM
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Biscuit Th: 1.25"
Structural Wheel Housing
Scope: (1) 41-Sensor Systems
Die: 1-Cavity
DCM: 1,800T
Improvements:
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Passed Mech Prop Requirements
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Productivity Eliminated 2nd DCM
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Reduced Cycle Time 25%
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TCUs Reduced 67%
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Die Spray Reduced 90%
Before:
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Energy: 3 TCUs
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Spray: 0.32 gal/cycle
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Spray Dilution: 90:1
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Cycle Time: 67 sec/cycle
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Capacity: >1 DCM
After:
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Energy: 1 TCU
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Spray: 0.03 gal/cycle
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Spray Dilution: 45:1
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Cycle Time: 50 sec/cycle
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Capacity: 1 DCM