The challenge
The task that a leading European tool manufacturer presented us with was quite a challenge: A complicated turned part with a hexagon socket and lateral milling needed to be manufactured.
At that time, the part was manufactured in 6 work steps in southern Europe. The switch to manufacturing in Asia was, above all, to bring much-needed cost savings.
The special nature of the task
It wasn’t just the customer’s target price that was ambitious. The required tolerances of < 0.03 mm for the hexagon socket were also difficult to achieve. Accordingly, the initial samples of the processes currently used in Europe were disappointing.
The Dakoko solution
It quickly became clear that a completely new production strategy was needed. For this purpose, we first identified the machine type that offered the best processing-time to acquisition-cost ratio.
It also had to be possible to carry out the entire processing on just one machine. This led to the decision to use particularly robust sliding headstock lathes. Feasibility studies were then carried out, samples produced and a pilot series run. Volume production was then launched.
Details that make the difference
The crucial innovation was the elimination of the various process steps that were previously necessary. By manufacturing in a machine without any manual handling, the process could be stabilized to the greatest extent possible, and the quality of the parts increased.
After amortization of the equipment purchased specifically for this customer, the price was further reduced according to plan. This was already set out in the multi-year contract.
In addition, further optimizations were implemented in the areas of machining and tool design, further increasing productivity and even reducing costs for the customer beyond what was contractually agreed.
Benefits for the customer
- Sustainable reduction in manufacturing costs
- Full compliance with quality standards