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Category Archives: Project Spotlight

A Customer’s Pain Point and a Deep Draw Solution

Deep drawn stainless steel enclosure tubesA leading American company of water and gas distribution products reached out to us with a problem with one of their metal components. The current design of this tube included a seam that required a secondary weld operation. The essential function of the metal tube was to stiffen the connection between the water line of flexible PEX tubing and a brass lock nut for the inlet valve into the home. The tube alleviated the compression force at the junction with the locking nut and provided the rigidity to prevent creep of the PEX line. 

The assembly process consisted of inserting the tube into a plastic sleeve. The fit between the tube and the sleeve was problematic.  Because of the welded seam’s inconsistent  surface finish, the fit between the two parts led to hang ups and misalignments because of burrs. The condition had become unacceptable to the customer because of both a scrap rate and concerns about the product performance in the field.

The customer did not have much familiarity with deep draw metal stamping applications.  Their engineering and purchasing team conducted a thorough review of the Prospect Machine Products’ website and contacted us. What had caught their eye was a number of tube-shaped components featured in our photo gallery, all without seams, since deep draw stampings are all formed with a solid wall around the entire diameter. Through a series of remote meeting collaborations and deep draw metal forming design assistance, a revised print was issued, a quotation was prepared, and tooling orders for two versions of the part were placed.  To ease the assembly for the re-design, we also proposed a formed taper to the tube at the start of the insertion, and they agreed wholeheartedly.  We also included a radial product identification stamp on the exterior side wall.  No easy feat since the material was 304 stainless steel.

This is not the first time we have eased a customer’s pain point with the solution of deep draw metal forming over other methods of metal fabrication, including castings, machinings, four slides, and swagings. Our experience with the conversions to deep draw have had outcomes of lower scrap rates, lower material usage, and more consistent productivity with high volume sub-assembly and assembly work.  All in all, lower costs to our customers.

We now have a new and highly satisfied customer with parts volumes in the hundreds of thousands and the potential for more growth from new projects.

Have a deep draw metal stamping project that would be best handled by a provider that truly understands the customer experience and is committed to your success? Contact us! Email info@pmpdeepdraw.com or call 203-758-4448, X25 for our Sales Manager, Nicole Spaeth.

PMP Awarded New Business with Leading Security Hardware Company

 

deep drawn forming for security hardware

PMP Awarded New Business with Leading Security Hardware Company

One of the largest companies in security hardware selected Prospect Machine Products as a key supplier for numerous deep draw components. The company learned of us through the technical chat on our website, pmpdeepdraw.com, and shared prints during a video conference for a quote.

After providing the estimate, PMP was selected as one of six deep drawing manufacturers to get further consideration. Following a site visit by a corporate team and a subsequent audit, the customer awarded us the work consisting of numerous new part numbers.

Challenges and Opportunities

Each of the jobs we were awarded required a complete set of new tools. This was a formidable challenge for a small manufacturer of deep draw metal stampings. However, we chose to view it as an opportunity to excel and utilized our project management tools along with customer-specific project management requirements to keep our teams on task. 

We also held weekly video conferences and teleconferences over the next nine months to guide the development of the new deep draw tooling for all the jobs. Internally, we met weekly with team members from all disciplines, discussing our tooling benchmarks and updating our Gantt chart for each job before our weekly conference with the customer.

Gantt Chart of the Deep Draw Process

A Focus on Safety

Safety was the customer’s highest priority since it’s essential that their products remain functional in a variety of harsh circumstances. I had the opportunity to tour their production facility and watch various product tests. These assessments focused on repeatability and reliability, with cycle counts into the millions. Many of the tests were conducted for product endurance in severe conditions such as extreme heat and with impact shock factors.

Since deep draw components are a large part of their assembly process, it was critical that these elements demonstrate blueprint dimensional conciseness resulting in positive fit and function for the product, and contributing to its safety.

Have a deep draw metal stamping project that would best be handled by a collaborative partner like Prospect Machine Products?  Contact us! Email info@pmpdeepdraw.com or call 203-758-4448, X25 for our Sales Manager, Nicole Spaeth.