Case study of introducing alternative processed products: Request for resolution of confusion from an automotive parts manufacturer.
Achieve up to 3 times the number of shots! Improve the tool life of punch tools with variability!
During a visit to a car parts manufacturer we have been working with, we discovered a large quantity of used punches. A 200L drum was filled with used punches measuring Φ8×27mm. Upon inquiry, we learned that the quality of the punches currently being purchased is unstable, leading to variability in tool life and making it difficult to calculate replacement timing, which has caused confusion. We promptly introduced the designer of the punches and conveyed the situation on-site. Although the designer was at a loss, they explained a rough outline of a proposed solution based on their previous experience with custom machining, which led to the response, "Please go ahead with Bandai!" When we proposed an improvement plan using metal film coating to keep costs down, we received feedback that they had previously attempted this but experienced early breakage instead. From that information, we hypothesized that the heat generated during the coating process might be the cause and began to take measures. As a result, the previously unstable usage count of the punches increased to an average of 15,000 shots, achieving a stable lifespan that is approximately three times longer. *For more details, please refer to the PDF document or feel free to contact us.
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【Request Details】 ■Product Name: Punch for Pin Clamping ■Current Situation: The replacement cycle for the punch, which is a consumable tool, is unstable at 5,000 to 10,000 shots, making it difficult to calculate the timing for replacement. Although the cause has been investigated, no clear answer has been found. ■Issue: Achieving a stable long lifespan for the punch through improvements in wear resistance, abrasion resistance, and chipping resistance. 【Summary】 In punch manufacturing, the important tip is usually finished by grinding. While wire cutting can achieve efficient finishing, it introduces heat that can compromise the hardness of the tip. However, in cases like this one, where parts are frequently replaced, the labor and cost associated with grinding finishing are not suitable. Amid conflicting conditions, the decision to select "SKD11 high-temperature tempered material" for the base material was crucial in achieving mass production through wire cutting while avoiding thermal effects during metal coating. *For more details, please refer to the PDF document or feel free to contact us.
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For more details, please refer to the PDF document or feel free to contact us.
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The concerns faced in the daily procurement of custom-made processed products, such as "not arriving on time," "unstable quality," "unable to process according to the drawings," and "existing suppliers going out of business," among others. Bandaï's proud custom processing procurement network, the "Hometown Processing Network," consists of unique processing companies from various regions including Hyogo, Osaka, Shimane, Tottori, Hiroshima, Aichi, Kanagawa, and Ibaraki, and it leads to solutions for a wide range of issues related to custom-made processed products. Additionally, in recent years, we have also established a procurement network with reliable overseas processing companies, the "International Processing Network," to strengthen our ability to resolve cost-related concerns.