Kiliyaan bi: Fournisseur d'automobiles européen de moyenne
Usine: oto Structural Brackets
Lu jëm ci projet bi: matris bu dox ndànk Design, Manufacturing & Mass Production
Partner: MetalStampingParts.ltd — Precision tëggin metal ci matris defarkat, China
1. Background kiliyaan bi
Sunu kiliyaan bi, ab furnisër bu mag bu Tier 2 di liggéey ci benn OEM oto bu mag ci Europe, defar na bracket yuy dooleel asiye yu ñuy jëfandikoo ci montage subframe yi ci kanam. Wàll wi - ab bracket asiye buñu laule ci sedd bu am yaatuwaayu 2.8 mm (grade SAPH440) bu am yaatuwaayu 120 mm × 85 mm - dafa am solo lool ci wàllu kaaraange, ndax dafay laaj liggéey bu méngoo ci wàllu mekanik ci liggéey bu bari.
Bi ñuy jëflante, laaj bi kiliyaan bi laaj ci at mi tollu ci 2,000,000 piyees, ak ay projection ci siklu dundu buy dem ba 7 at. ñeenti-gaaraas yu benn jumtukaay jëfandikoo: fomp, bënn, forme, ak tapping bu nekk ci ñoom def ci pres mekanik yu wuute. Liggéeyukaay bu xaajaloo bi laaj na ñeenti operatëru masin, ñeenti tabb pres, ak inventaire bu am solo ci liggéey bi ñuy amal (WIP) ci diggante gaaraas yi. Njëg li ci piyees bu nekk wàccina ba $1.82, muy lim bu ekipu jëndkat yi jàpp ni du mëna wéy ndax seen kiliyaan OEM dafay gëna yokk njëg yi.
Kiliyaan bi dafa jege nu ak lu leer: wàññi njëgu benn yoon ci suufu $1.20 ci noonu lañuy yokk ñaari yoon li ñuy def weer wu nekk daale ko ci 80,000 ba 160,000 piyees — lépp te baña yàq ±0.05 mm tolerans dimensionel yiñ soxla ngir soudure robotik otomatik ci ligne OEM's assemb.
2. Jafe-jafe bi
Ñatti mbir yu boole seen biir ñooy fësal jafe-jafe teknik bi ci projet bi:
Njëg yiñ nara fay. Njëg li fi nekk di $1.82 waroon na wàññeeku lu mu néew 34%. Ci 2 milioŋ ciy unité ci at mi, loolu dafa tekki ni dañu sakkanal lu ëpp $ 1.2 milioŋ ci benn at model - laaj bu amul benn njariñ ngir benn pàcc bu mag buñ jota optimize ci ay at yu bari ci liggéey kaizen.
. Lignéeru benn liggéey bi mën na génne 80 000 piyees weer wu nekk ci ñatti turnu. Projection yi laaj nañu 160,000 piyees/weer ci diiru 18 weer. Sooy duppi jumtukaay yi fi nekk rek, fàww nga yokk $240,000 ci xaalis biy dugg ci jumtukaay yu dëgër yi, boole ci bayaalu dëru usine bi kiliyaan bi amul.
Muñ buy gëna bari. Ak ñeenti jumtukaay yu wuute ak ñeenti cycle yu aju ci sargal/dechargement, liggéey bi dafa dajale njuumti ci positionnement. Fexe am ±0.05 mm ci dimension critique pax mi ba ci catu pax mi dafay laaj 100% inspection ci ligne bi ak jumtukaay yu bari yuy faral di defar, dawal liggéey bi ak njëgu mbalit mi. Bépp pexe mu bees dafa wara dindi yii balluwaayi njuumte yu bari.
Kiliyaan bi itam yor na 4,7% ci biir, lu gëna bari ci njuumte ci ñaareelu gaaraasu formaasioŋ ak tapping.
3. Sunu saafara
Ginaaw ñu defee jàngat bu leer ci jëmmal defar (DFM) ak ekipu ingenieur kiliyaan bi, nu tànn benn 18-station matris bu dox ndànk boole bépp liggéey ci benn siklu pres bu wéy.
3.1 Layout strip ak jëfandikoo jumtukaay
Benn levier bi gëna mag mooy macceer bu bees. Li ñu njëkka def mooy jëfandikoo benn strip bobine bu yaatuwaayu 140 mm ak benn rang, mu jur 68% jëfandikoo jumtukaay. Sunu ekipu ingenieur yi jëfandikoo nañu AutoForm-based forming simulation ngir gëna dëggal rang bu 3 rang (zigzag) ak gëna xéewale strip porteuse. Layout bu bees bi dafa wàññi strip bi ba 108 mm ci rang bu nekk ci ñatti rang, mu am 92% jëfandikoo jumtukaay - 24-poñ ci teemeer boo jél, loolu kese moo waral lu tollu ci $0.28 ci piyees bu nekk.
18 gaaraas yi ñu ngi leen jëmmal ci anam yii:
| Gaaraas | Operasioŋ |
| 1 | Pilot hole punching (Ø6.0 mm, 2×) |
|---|---|
| 2–3 | Dagg buy yokk & ñaq ci biir |
| 4 | Idle (zone de armature structurel) |
| 5–6 | Palanteer bi ci biir (xar yu gudd, 12×5 mm) |
| 7 | Courbure préformation (45° bride partielle) |
| 8 | Ractif |
| 9 | Courbe de forme finale (90° ± 0,5°) |
| 10 | Restrike / coining for bend radius control |
| 11 | Relief (perle d'arrigissement, hauteur de 1,2 mm) |
| 12–13 | Bride (courbe Z, ñaari wetu yi benn yoon) |
| 14 | Ractif (zone de contrôle du capteur) |
| 15 | Dagg pax mu jaar yoon (Ø8.2 mm ± 0.02 mm, 4×) |
| 16 | Tapping — integrated in-die servo tapping unit (M6×1.0, 2×) |
| 17 | Taqaloo / dagg |
| 18 | Dagg scrap |
3.2 Jumtukaay Asie & Tanneef Coating
For the high-wear stations (piercing punches, forming inserts, and the tapping station), we specified SKD11 (JIS G4404) jumtukaayu liggéey bu sedd buñ dëgëral ba 60–62 HRC, ak TiCN (Carbonitrure de Titanium) Couche PVD ñu koy jëfandikoo ci bépp surface buy dagg ak defar. Njaxas moomu dafay joxe surface bu dëgër bu ëpp 3,000 HV, di yokk dundu jumtukaay ba ci 5 millions de coups diggante defar yu mag - lu am solo ci prograamu 2M / at.
Ponku njiit yi ak bushings yi leeraloon nañu ko ci SKH51 acier à haute vitesse ak ay retenteur de cage à boule ngir mëna am njubte ci 0.003 mm ci biir press bi yépp.
3.3 Mboolem
Amaana li gënoon am solo ci wàllu xarala mooy boole M6 × 1.0 liggéeyum tapping ci die progressive bi ci Station 16. Sunu jëmmal jëfandikoo servo-driven in-die tapping unit synchronisé ak angle crank pres, yegg 50 coups ci simili bu nekk ci gaawaay ak evacuation puce otomatik. In-die tapping dindi na benn position operatër bu mat sëkk ba noppi wàññi njëgu tapping bu nekk ci $0.09 wàcci ci suufu $0.02.
3.4 Simulation-Driven Similation
Laata ñuy dagg asiye, danu daw:
– Forming simulation (AutoForm R8): Sewluwaay buñu gëm < 20%, jëmmal bu amul rës, kompensaasioŋ bu am ressort bu 0.8° ci bride 90°
– FEA structurel (ANSYS): Tension die firndeel ci suufu 980 MPa ci bépp insert bu am solo ci 250-ton pres sarge
– Kinematiku yokkute strip: Pilot bi dafa xool bu baax ci bépp gaaraas, yaatuwaayu porte bi gëna ndaw 8.5 mm ñu toppatoo ko ci
Simulation bi njëkka defar dafa wàññi test physique yi daale ko ci 5–7 yoon yu ñuy faral di def ci liggéeyukaay bi, wàcci ba 3 yoon kese.
4. Doxal
4.1 Kalendriye defar
| Faas | Duration | Jaar-jaar yu am solo |
| DFM ak jëmmal | Ayu-bis 1–2 | Simulation-validated layout signed off |
|---|---|---|
| Design die (3D CAD) | Ayu-bis 2–4 | Full SolidWorks assembly with 478 components |
| Jënd macceer bu bees | 2-3 ayu-bis | SKD11 blok yu bawoo ci Hitachi Metals |
| CNC ak EDM ci kable | Ayu-bis 4–7 | Usinage à 5 axes + EDM de fil sodick pour découragement de perforateur/matre (6-8% de l'épaisseur du matériel) |
| Montage & Raccord banc | 7–8 ayu-bis | Die set assembly, guiding alignment verification |
| Tryout — Round 1 | ayu-bis | Tampoŋ bu njëkk bi, gis nañu ñatti barab yu ndaw yu am burr |
| Jéem - Round 2 | 9 ayu-bis | Burrs saafara, dellu ci biir muñ |
| Jéem — Round 3 | 9 ayu-bis | PPAP bu mat sëkk: 300 piyees, dimension yépp ci spec |
| Liggéeyukaay ak samp gi | ayu-bis 10 | Die yobbu, samp ci kiliyaan 250T AIDA pres |
Tolluwaayu liggéey bi daale ko ci komànd bi ba ci waajal defar ci lu bari: 10 ayu-bis.
4.2 Resultaa yi ci xët wi njëkk
Ñatteelu jéem bi ak bu mujj bi jurna 96% rendement bi njëkk ci 300 xeetu PPAP. Saytu jëmmal ci CMM Zeiss CONTURA firndeel nañu ko:
- Bépp 47 màndarga dimensionel ci biir mën mën
– Cpk ≥ 1.67 ci 12 màndarga yi gëna am solo ci kalite (CTQ)
- Amul natt bu génn ci misaal bi yépp
4% bi des ci ñàkka méngoo dafa yam ci scuffing bu ndaw ci kaw perle relief - ñu saafara ko ak 0.5 μm yokk ci punch surface finish (Ra 0.5 μm polis).
5. Resultaa yi
5.1 Njëg li ñuy xaaj (Pièce bu nekk)
| Element Coût | Balaa | Ginaaw | Coppite |
| Matériau premier | $0.74 | $0.46 | ↓ 37.8% |
|---|---|---|---|
| Liggéey bu jub | $0.38 | $0.09 | ↓ 76.3% |
| Amortisasioŋ masin | $0.28 | $0.21 | ↓ 25.0% |
| Consumables & tooling | $0.15 | $0.12 | ↓ 20.0% |
| Scrap & rework | $0.08 | $0.02 | ↓ 75.0% |
| Overhead allocation | $0.19 | $0.25 | ↑ 31.6%* |
| Total | $1.82 | $1.15 | ↓ 36.8% |
Yokkateg njëg bi dafa yokk ndax tonnage bi gëna bari ci press bi;
5.2 Jawriñu liggéey
| KPI | Baseline | Def nañu ko | Bibluwaay |
| Unit cost | $1.82 | $1.15 | $1.20 |
|---|---|---|---|
| Kàttan weer wu nekk | 80,000 pcs | 180.000 pc | 160.000 pcs |
| Kàttan liggéey (Cpk) | 1.12 | 1.67+ | 1.33 min |
| Jëfandikoo jumtukaay | 68% | 92% | — |
| Njëg li ci biir | 4.7% | 0.8% | <2.0% |
| Operator count | 4 | 1 | — |
| Jamonoy coppite | 45 simili | 8 simili | — |
5.3 Sakkanal at mi
. $1,340,000 ci wàññi njëgu at mi. Dugal xaalis bu mat sëkk (lu tollu ci $ 185,000 boole ci jëmmal, jumtukaay, masin, coating, ak tryout) def payback ci diir bu néew 9 ayu-bis de production.
6. Xalaatal kiliyaan yi
"Liggéey nanu ak ay naataango yu bari ci Asie ci 15 at yi weesu, te projet bi dafa bokk ci 15 at yi weesu. simulation-first approach dafa tekki ni sunu ekipu ingenieur yi dañu amoon wóolu seen bopp bu mat sëkk laataa ñuy dagg asiye bi, mu dawal pàrti yu baax yi ci diiru ñatti turnu 37% wàññikug njëg bi weesu sunu mébet bu njëkk, te - amaana li gëna am solo mooy - amul benn dayo. zero kiliyaan bañ traceable dimensionnel jafe-jafe boobu xeetu kalite mën mën la sunu kiliyaan OEM laaj.
— Direktëru Ingénieur, Furnisëru Oto bu Tier 2 ci Ëroop
Tur wiñu tëye ci NDA
7. Njariñ yu am solo
🔗 Xoolal itam: Jàngat misaalu tëggin bu jaar yoon ci aparey medikaal - Noo ngi amee ±0.01mm tolerans ci 0.15mm 304 acier inox ngir benn kompiñi buy defar ay aparey medikaal ci Etats Unis, wàññi njëgu komponent bu nekk ci 53%.
1. Consolidation die progressive nekkul lu jëm ci gaawaay rek - lu jëm ci dindi njuumte la. Saa yu ñu dindie benn pàcc ba noppi defaraat ko, dafay indi risku muñ. Design 18-gaaraas yi dindi nañu ñetti poñ yuñ mëna toxal, ba noppi kàttan liggéey bi dafa yokk joge ci Cpk 1.12 dem ba 1.67+ muy résultat bu jub.
2. Jëfandikoo macceer mooy faral di nekk levier bi gëna mag ci njëg - te dafay faral di gëna néew luñu ko optimiser. Yokkateg 24 poñ ci teemeer boo jél ci njuréefi macceer bi moo gëna yokk sakkanal piyees bu nekk moo gëna wàññi liggéey bi. Layout yu bari-rang yuñ jagleel, suñu ko gëmee ci simulation, mën na tëj sakkanal macceer bu dramatik te du yàq formabilite bi.
3. Ci biir matris ñaareelu liggéey (tapping, soudure, montage) dañuy laaj xarala yu bari waaye dañuy soppi jënd ak jaay. Servo tapping bi mooy sub-system bi gëna xawa jafe ci matris bi, waaye mingi dindi bépp liggéey bu nekk ci off-line ak operatër bi, wàññi 78% ci njëgu tapping bi.
4. Dugal xaalis ci simulation dafay fay boppam ci diiru jéem bu gàtt. Ñatti rond tryout ci barabu 5-7 rond yi ñuy faral di def ci liggéeyukaay yi, dañu sakkanal lu tollu ci $12,000 ci waxtu taskatu xibaar yi, macceer, ak waxtu ingenieur yi - lu tollu ci 3× njëgu liggéeyu simulation bi ci boppam.
5. Jumtukaay asiye ak tanneef coating war nañu méngoo ak koom-koomu prograam bi. SKD11 + TiCN moo gëna baax ci prograam bii di 7 at, 14 milioŋ ciy piyees. Ngir volume yu gëna rëy wala macceer yu gëna abrasif, danuy gëna digal grade metallurgie poudre (lu melni, ASP series) wala yeneen coating (AlCrN ngir aplikaasioŋu tàngoor wu yéeg).
Lii jàngat dafay wane ab projet bu MetalStampingParts.ltd amal. Yenn leeral yiy xàmmee kiliyaan yi dañu leen nëbb ci ndigalu kontraa biy tere ñu joxe leen. Lépp lu jëm ci done xarala yi, lim njëg yi, ak jagleel performance yi dañu leen di saytu ci këyitu projet bi ak ci audit yiñ def ginaaw bi ñu defaree projet bi.
Soo bëggee laaj lu jëm ci jumtukaayi matris yuy yokk, ingenieur yuy wàññi njëg yi, wala jàppante ci estampoŋ wen wu bari, jokkool ak sunu ekipu ingenieur yi ci MetalStampingParts.ltd.
Related Resources
- Jàngat misaalu wàññi njëgu OEM ci oto - Naka la gëna dem ba gëna xéewale wàññi njëg yi ci 37% ngir OEM oto.