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1 Million Dollar Pacific Machine ROI in Just 12 weeks

The new high tonnage press decreased scrap rates, reduced cycle times to just 90 seconds per part,
and reduced overall manufacturing expenses. How did they do it?

Objectives & Background

A North American Tier 1 Automotive Supplier was looking for a faster, more efficient method of developing their rack and pinion gear set. The client was outsourcing a large portion of this job due to capacity constraints but was seeking to move this work back in-house with the completion of this project.

Pacific experts did a thorough analysis and discovered 4 addressable issues:

  • 3 set cycle process - The existing process caused long cycle times (5 minutes), inconsistent results, and high manufacturing expenses.
  • Long change-over time for different models -The manufacturer was changing dies multiple times a day, spending up to an hour on each die change. Significant production time and profitability was lost to tooling changes.
  • Material feed and handling system - The facility relied on an operator to load and unload the parts manually. This led to excessive material handling, and a bottle neck within the production process.
  • High scrap rates - Multiple inefficiencies within the current process created a high scrap rate, driving up the cost per part.

Pacific’s Solution

  • Pacific designed a high tonnage press specifically for the customer’s products, providing consistent, more accurate gear formation.
  • A robotic material delivery system was developed to load and unload parts in the production process.
  • A custom die change system was created, which reduced die change-over time from 1 hour to just 15

Value to the Customer

  • The new high tonnage press decreased scrap rates, reduced cycle times to just 90 seconds per part, and reduced overall manufacturing
  • The material handling improvements seen in the robotic arm system greatly reduced cycle times (more accurate part positioning), scrap rates, and material handling
  • There was a 75% reduction in die change over time with Pacific's new system, which reduced costs/part, increased output and made die changes quick and easy for
  • In total, the new system designed by Pacific was approximately a million dollars. Despite the expense, the efficiencies and improvements seen in the new system enabled the customer to see a return on their investment in just 12 short weeks!

Now that’s SOLUTIONS, DELIVERED.