The time is now to do it right.
Are you losing customers due to high scrap rates and lower production levels? Quality influences every aspect of your business – from meeting customer expectations to managing costs to your company’s reputation. Customers expect you to deliver the highest quality product and reward you with their loyalty when you do.
Understand how quality and accuracy help you deliver to customer expectations.
Meeting Quality Standards
The Automotive Division of American BOA in Cumming, GA, contacted OASIS when one of their hydroforming machines would not produce straight parts. The American BOA team were unsure what area of the machine was out of alignment, but could clearly see that the parts produced did not meet their straightness quality standards.
OASIS was called in to inspect this machine and two others that were having possible alignment issues. After an initial meeting, it was decided that the best solution would be to have an OASIS metrology engineer complete an in-depth inspection of the first machine using a laser tracker – and because of production volumes at this facility, an OASIS expert was needed immediately. Li Guan, OASIS Metrology Engineer out of the Canadian Service Center was first on site. Using a laser tracker, he inspected various components as directed by the American BOA team. With the software utilized by the laser tracker, Mr. Guan built a model of the machine that showed both the out-of-level condition and the misalignment of its cylinders. Since the model was created while onsite, Mr. Guan was able to work with the American BOA team to successfully make the necessary alignment adjustments. Because this was done so quickly, American BOA was able to expand the job scope to utilize Mr. Guan’s expertise on the two other machines within the two-day time initially allotted. With the assistance from OASIS, American BOA was again able to produce parts that met their quality standards for straightness.
Substantial Quality Improvements
A large manufacturer of plastic film products began receiving feedback from several of their customers stating that the final product did not meet their quality standards. The engineering group at this facility, hired OASIS to perform a thorough inspection of the components within the line in order to determine if misalignment was the cause of the quality issues.
Using optical alignment tooling, the OASIS team performed an initial alignment survey of the rolls in the line. This inspection found that the overall alignment of the rolls was acceptable. However, there was significant misalignment at the unwind and rewind turrets, as well as in the accumulator. OASIS worked with the team from this location to develop a plan to address the major alignment concerns. The plan involved having OASIS perform a complete alignment of the line using optical alignment tooling and the mechanical capabilities of an OASIS large tool crib/truck. A seven-person OASIS team was able to complete this project in one 10-hour shift. This project resulted in improved film tracking and a substantial quality improvement that now met their customers’ stringent requirements.
Paper Mill Wins Back Customers
When a paper mill began losing customers due to poor product quality, including severe wrinkles and other paper defects, they knew they had to find a solution to these issues in order to win customers back and avoid losing additional customers. It was clear to the mill that there were runability issues in the first dryer section including baggy edges, wrinkles, and uneven heat transfer across the width of the web – resulting in unequal drying.
Additionally, gear clearance had bottomed out causing vibration analysis to be nonfunctional. OASIS was hired to perform a mechanical alignment of the first dryer section of the paper machine. This project included setting gear clearances, adjusting dryer cans for the vertical and horizontal attributes, aligning the pocket felt rollers and aligning the entire upper felt unirun section. Since the completion of the alignment project, the mill has seen a big improvement in product quality. Additionally, many of the machine runability issues have been eliminated. The mill’s project manager commented “thank you for the excellent work. . .the first top dryer felt run is the best I have seen it”.
I can’t even express in words how impressed I am . . . your engineer made suggestions to me and my staff, provided step-by-step explanations and ultimately got our machines back up and running like never before. . .
Learn how the advancements made in portable dimensional metrology bring immense value to manufacturers and the energy sector. LISTEN to this 15-minute podcast now.