Set Up Time Reduced 20 Minutes per Job
Mate’s Ultra UMT™ Multi Tool Means More Machine Uptime
A leading manufacturer of truck and SUV accessories had been using a laser to produce parts featuring its company and product logos, which were very complex. They wanted to produce a higher yield within a specific run time. Specifically, they wanted maximize production to include part nesting but the laser wasn’t up to the task. So, the company decided to look at punch presses and engaged Mate Sales Engineer John George for assistance..
ULTRA UMT™: THE RIGHT TOOL FOR THE JOB
After reviewing the needs, John thought that the complexity of the logo required a turret with a large station/bore capacity. Prima Power believed it had the right machine for the job, so John worked with the customer and Prima to review the details. He concurred that the Prima would be able to handle the complex project much more efficiently than a different press. The shapes used to create their logo consumed 14 stations alone, so they needed something that would provide extra capacity. To maximize turret capacity, John recommended Mate’s Ultra UMT multi-tool that also has the benefit of fewer tool changes. Fewer tool changes mean more machine up-time. It was the right tool for the job. Ultimately, the company purchased a Prima Power Punch Genius.
John believed operator training was essential to the success of the new machine and developed a program for the customer. Although the company has Amada machines, the Prima Punch Genius would be the first of its kind to be used by the customer. Even though the operators were familiar with thick turret tooling and UltraTEC, the Ultra UMT multi tool would be a new concept to them, so they would need to learn how to properly use and maintain it.
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REDUCED SET UP AND MORE
First, John explained the benefits of using the turret’s full capability and the correct tooling to add more green light time for production. John then trained the staff in the proper use of the Ultra UMT multi tool. Ultra UMT added 14 extra punches to the turret, so more tools per station reduces the down time to change tools. By doing so, they reduced an average of 20 minutes per set up.
- At a $50.00 shop labor rate with 2 production shifts, the company saved $8,433 in labor dollars and gained back 169 hours of labor.
John also spent time training the Machine Operators on the importance of machine maintenance, and how to identify worn or damaged tooling. Most customers see a minimum 3%-5% productivity improvement and a 3% reduction in tooling costs with proper machine and tooling maintenance.
- At 2,024 hours per operator X 2 operators/machine at a $50.00 per hour shop labor rate X 3% productivity gain = $6,072. A 3% reduction in punch and die purchases $168,193 x 3% = $5,046 for a total of $11,118.