After met the customer at Shenzhen Airport East at 8:00am in the morning of July 26, we with the customer to visited the Dongguan factory for on-site product testing and confirmation. This is the third time customer came from Japan. At present, the new case is about the stamping die parts. Because the product is so long that the tolerance of the used surface (R surface) is only 0.01MM, and the product processing is easily deformed, this is very difficult to do the product.
After communicating with customers, they had a cooperative manufacturer in Japan. However the cost is very higher and there is no competitive advantage then others , they have to find a new manufacturer. In Japan, they also found 3 to 4 manufacturers to quote, the price is still higher, so that current situation wants to find suppliers in China.
In fact, in China customer still looking for suppliers, but looking for several companies have encountered the same problem has not been resolved: item 022 and item 023 is a set, item 022 uses two pieces of symmetrical combination, and then mounted on item 023 Used, so the size of the fit R10.5 is very important, because R10.5 is only a quarter of the size, regardless of the use of the CMM or profiler in the measurement, the error of the fit is very large, take the point data The difference in the range of measurement results is far away, cannot meet the tolerance requirements of 0.01, plus the measurement found that the center of the fit has an eccentricity of 0.03 to 0.05, which will make the two pieces of item 022 and item 023 pieces cannot be loaded, and will cause the surface plane segment difference, affecting the use. Such traditional measurement methods or sophisticated inspection equipment cannot detect the experience of the two assemblies.
These two sets of products are consumables on the mold. If this problem is not solved, the whole set of molds will have problems. The initial proofing is done by wire cutting (cut 1 repair 3), and the wire cutting length is longer during the proofing process. However, the thickness of the product is relatively thin, and the amount of deformation of the product is difficult to control, so that expected effect is not achieved. The Fujipunch team once again met to review and adjust the processing plan. First, the deformation amount was controlled, and the R surface was processed by grinding. Thereby controlling the defective rate and reducing the cost. From the measurement results of this trial work, the expected results were achieved.
The customer’s project is a long-term order, with dozens of sets of requirements per month. So we needs to consider the processing technology of mass production in future.
After 7.8 times internal review meetings, in view of the current preliminary plan of Fujipunch team, combined with the preliminary test evaluation, in the subsequent mass production, starting from the shape of the grinding wheel, the shape of the grinding wheel is made into the surface of the ground product. The shape improves the grinding accuracy while reducing the processing cost. At the same time, we improve the detection method, no longer use the traditional detection method, just guarantee the product tolerance and cannot guarantee the product experience. From the user’s point of view, although the product does not mark the R center of the two products to be concentric, but In order to improve the experience of use, the two products are assembled together, the concentricity should be less than 0.01, in order to solve the R10.5 center eccentricity, and the R10.5 size measurement error problem, optimize the use of the vertical two planes (see below Figure AB plane) Establish the military coordinate system, switch to the polar coordinate system, measure the point on the R10.5 surface, the actual polar radius value needs to be within the tolerance range, so as the standard detection, the optimization method solves the R10 at the same time. The problem of large fitting error and the problem of center eccentricity improve the experience of using the product.
Modern society is changing with each passing day. Market competition is very cruel. Enterprises must be bigger and stronger, and they are always in an invincible position. One of the most important points is how to reduce costs under the premise of ensuring quality. The improvement of Fujipunch processing plan every time seems to be inconspicuous, but the accumulation of small and small, while solving problems for customers, it also enhances the competitiveness of enterprises.
This special trip to the customer was very satisfied, and he was very impressed with Fujipunch plan, as mentioned that the next case also hopes that we will discuss the cost-saving plan together.
