OPEN UP TO QUICK-CHANGE, MODULAR WORKHOLDING
General News

OPEN UP TO QUICK-CHANGE, MODULAR WORKHOLDING (Case Study)

Case Study: Toronto Mold & Die Shop Cuts Set-up Time by 90%

With forty years under their belt, 120 employees, multiple customers with different machining and material demands, and a successful business, the shop turned to Jergens in 2015 to explore options for a better way. A better way to hold the large variety of components that the shop had grown to manufacture for its customers in the mold and die industry. They did, and they did it so well it earned them a reputation in the industry as ‘the aluminum experts’.

The Workholding Challenge

The shop had to build and maintain over 150 different custom fixtures of widely varying configurations. Furthermore, products produced spanned eight different categories, required expertise in CAD, engineering, prototype parts, machining operations including five axis, tooling and the list goes on.

In addition to ordering a range of steel sub plates, fixture plates and numerous clamping components to make the fixtures, the shop also had to machine and assemble them. So, before a single chip hit the floor from a customer part, they had to make their own set ups. They did well, obviously they are a skilled shop, but realized that a better solution had to exist.

Jergens Workholding Solution

By choosing Jergens, and their Zero Point System (ZPS), the shop was able to accomplish three things immediately: refocus on their core business as an expert manufacturer of components within the mold and die industry, secondly, implement a far superior system and lastly, achieve tremendous cost savings.

The ZPS mounting system is a real game-changer for the industry and provides two key advantages – speed and repeatability, less than 0.005mm (0.0002”). The speed part of that equation is that, with ZPS, users can fix, position and clamp all in one step, saving set up time in many cases by as much as 90%. There are many options within the ZPS including units that feature either pneumatic, hydraulic and manual actuation. A newer style even features a clamping module with sensors to provide clamping force feedback. A range of clamping plates, pull studs and mounting styles are also all part of this robust workholding solution.

The Results

For the shop, the biggest realization (economic impact) came from the analysis of the true cost to manufacture and assemble the fixtures, and the incredible reigning-in of set up time – 90% reduction. Prior to the Jergens ZPS solution, the time it took for each set up was ten minutes, and there was an average of thirty setups – that’s five hours per day spent just in setup time. That average time with the change to ZPS went to just one minute, or one-half hour total per day. At a rate of $100 per hour, that’s $450 per day in savings, or $112,500 annually

Tom Reid, Canadian Sales manager for Jergens, who works very closely with the shop, reported, “I’ve seen a lot of positive results, particularly with Drop and Lock (another popular quick-change pallet option) and ZPS, but don’t recall one as dramatic as this in recent years”. Tom continued, “We work closely with the customer to engineer and provide these solutions, and also measure important calculations such as ROI, which in this case was about five weeks”.

The end result for part production was significant and predictable - error reduction, reduced scrap, easy part orientation, and better / more consistent output from the manufacturing floor.

 

 

General News, Uncategorized, Workholding

Primary Considerations for 5 Axis Workholding

Lean your Machine - Multi Axis Top Tooling

Clearance and rigidity are the primary considerations when choosing the best vises and fixtures for 5-axis machining.  There must be adequate clearance for the cutting tool and part in their position to the table, providing sufficient space for the Y-axis, the fixture height and size of the part.
The goal when switching from a 3-axis machine to 5-axis is to reduce handling, tooling changes and cycle time.  It is all about a single set-up, or Done-in-One.  Because there is less handling in 5-axis machining the chance of error is minimized, providing more consistent quality parts.

Five-axis is often thought to be overkill for many shops that depend on 3-axis machines.  Yet, there are many operations where 5-axis is found to be more efficient for jobs where 3-axis is the norm.  The increase of accuracy and labor savings from reduced handling can outweigh the cost differential and provide a significant ROI.  As long as all components; fixture, vise, part and cutting tool are firmly set in place with enough clearance, 5-axis machining is by far the most accurate and efficient.
With the right multi-axis quick change system up to 90% of set up time can be saved by implementing a quick change fixturing system for a fraction of the cost of the cutting tool investment.  The Jergens Fixture-Pro® Multi-Axis Quick Change Fixturing workholding system gets the spindle and cutting tool close to the work piece in the optimal machining position.  This can be achieved regardless of the machine or workpiece.  Fixture-Pro’s modular approach provides a combination of subplates, risers and top tooling that is right for any set up.
One manufacturer virtually eliminated set-up time, from three hours to just minutes.  The operation realized a cost savings of tens of thousands of dollars and additional machine capacity of 750 hours annually.
To learn more about Jergens’ Workholding Solutions, visit us online: www.jergensinc.com/workholding.
General News, Quality Certifications

JERGENS, INC. QSLM SUPPLIER FOR QUICK RELEASE PINS

Cleveland, OH – January 9, 2013 – Jergens, Inc. is proud to announce that the company has passed its Quality Suppliers List for Manufacturers (QSLM) audit which was conducted on January 9, 2013. The purpose of the audit was to maintain the company’s approval as a supplier of Quick-Release Pins to the US Department of Defense. The criteria for passing the audit is similar to ISO9001:2008 standards, with more emphasis on certification and traceability to raw material physical and chemical properties..

By passing this important and comprehensive audit, Jergens, Inc., continues to operate as an approved supplier of Quick-Release Pins for use by the United States Dept. of Defense and all other federal entities which utilize these unique locking pins.

Jergens Kwik-Lok®, Quick-Release Pins were designed provide fast, easy, positive engagement and high holding strength for applications requiring frequent, repetitive use. Simple, smooth operation makes Jergens Kwik-Lok® Pins an ideal replacement for detent, clevis and cotter pins. Beyond military uses, other Kwik-Lok® applications include general industrial/manufacturing, aviation and medical, recreational and marine equipment.

The 17-4 PH-grade stainless steel construction of Jergens Kwik-Lok®, Quick-Release Pins permit installation in corrosive, wet and other harsh or caustic operating environments. Other available materials and finishes include heat-treated alloy steel and cadmium-plating.

Jergens Kwik-Lok®, Quick-Release Pin features & benefits include among others…

  • Rugged, durable construction ideal for extreme environments
  • Firm, even grip for smooth operation
  • Includes hole and ring for easy attachment of optional lanyard
  • Vibration-resistant
  • High impact resistance
  • Quick insertion and removal
  • Double-acting pins activated by push or pull motion
  • Multiple handle styles for a wide range of applications

Jergens Kwik-Lok®, Quick-Release Pins are produced under the following manufacturing standards:

  • NAS Number NASM 1334 – NASM 1348 is also available.
  • MS / NASM Numbers 17984-90
  • Special Military and Aerospace size and configurations are available.

For more Jergens Kwik-Lok®, Quick-Release Pins information visit www.jergensinc.com/site/showcase_KLP or contact the company at Jergens, Inc. at 15700 S. Waterloo Road, Cleveland, OH 44110-3898. Phone: 877-486-1454; Fax: 216-481-6193.

E-mail: info@jergensinc.com

General News

Ball Lock® Quick-Change System Now Available in Stainless Steel

Now available in high grade 17-4 stainless steel, Jergens popular Ball Lock® Quick-Change Mounting & Fixturing System can now be expected to provide a long service life when installed in the most extreme operating environments.

Jergens Ball Lock® Quick-Change Mounting and Fixturing System is the first of any fixturing system to be produced in high grade stainless steel. This move was driven by customers wanting to extend the benefits of Ball Lock® quick change and precision locking technology within corrosive, wet, caustic and similarly harsh manufacturing environments.

This development also enables the Ball Lock® Quick-Change Mounting & Fixturing System of stainless steel shanks, face or back-mount receiver bushings and liners, to also be used in NSF-regulated, medical-grade, and other purity-stringent manufacturing environments.

Ball Lock's popularity among both fixture builders and machine tool operators, stems from its ability to quickly and accurately locate fixtures onto machine tables. The ability to lock and unlock Ball Lock's shanks in seconds, permits the exchange of fixtures in less than a minute, with a position repeatability and accuracy of +/-0.0005" (+/-0.013mm) or better.

The Ball Lock® System utilizes a patented locking technology to securely hold fixture plates to subplates with up to 20,000 lbs. (9000 kg.) of hold-down force per shank. Fixtures can also be quickly exchanged between different machines when both are using the Jergens Ball Lock® Mounting System.

The Ball Lock® system can be configured to create lean-optimized solutions for the most demanding appliciation needs. The benefits of using the Ball Lock® system include:

  • Incredibly FAST setups and changeover
  • Powerfully strong holding forces
  • Combines locking and locating in the same motion
  • Eliminates the need for indicating on CNC machines

A complete range of stainless steel Ball Lock® accessories are also available including T-Slot nuts, tapered caps & nuts, lifting handles, Sine fixture keys, fast-acting Ball Lock® keys, pre-machined T-columns and 4-sided tooling columns, and Ball Lock® vises.

General News

JERGENS, INC. TO PRESENT ON BENEFITS OF QUICK CHANGE FIXTURING AT IMTS 2012 CONFERENCE

Cleveland, OH – August 23, 2012 – Jergens, Inc., one of the world’s largest manufacturers of lifting, workholding, and fastening solutions, will conduct a session entitled “Set Up Time vs. Cycle Time: The Profitable Benefits of Implementing Quick Change Fixturing” at the IMTS 2012 Conference in Chicago. The session (IMTS06) will be held on Monday, September 10, from 2:00 p.m. to 2:55 pm in room W195.

In the never-ending quest to increase margins and profitability, cost-saving measures traditionally focus on reducing cycle times, often without taking into account the considerable cost-saving benefits of reducing set up times. Jergens’ interactive presentation at the IMTS 2012 Conference will demonstrate the benefits of implementing a quick change fixturing system in 5-axis, horizontal and vertical machining centers, and 4th axis indexers and rotary tables.

The presentation will use a variety of field application examples, videos and comparative analyses to educate attendees on how reducing set up time can have a significant impact on profitability as compared to reducing cycle time. The presentation will also highlight how advances in quick change fixturing options and methodologies can help attendees:

  • Limit the number of set-ups required
  • Reduce tool change time
  • Minimize spindle down time
  • Free up additional capacity
  • Implement lean cells
  • Profitably take on smaller runs

To document the cost-saving benefits of quick change fixturing in real terms, attendees will be presented with methods for calculating direct savings from set up time reduction, savings achieved from reduced tool change time and calculation of recovered machine hours, as well as ROI for a typical installation.

To register for the session, visit www.imts.com or www.jergensinc.com. Visit Jergens at IMTS booth W-2312 to learn more about quick change fixturing trends and cutting edge systems.