Hydraulic manifold: from three setups to one
We moved a hydraulic system maker's manifold to a single 5-axis setup; scrap fell from 4.1% to 0.5%.
Sample case study: the customer and figures are fictional.
Challenge
A hydraulic system maker in Germany had its manifold machined in three separate setups. The reference lost between setups caused position errors at intersecting holes and parts that failed the leak test.
Solution
We moved the block to one setup on a 5-axis machining centre with a purpose-built fixture. Angled holes were cut in one program, and the first part was fully measured on the coordinate measuring machine.
Burr checks at intersections were added to the control plan as a process step.
Result
Setups went from three to one, and cycle time dropped from 46 to 29 minutes. Leak-test rejects fell from 4.1% to 0.5%, and lead time shortened from six weeks to three.
Before and after
| Measure | Before | After |
|---|---|---|
| Setups | 3 | 1 |
| Cycle time | 46 min | 29 min |
| Leak-test rejects | 4.1% | 0.5% |
| Lead time | 6 weeks | 3 weeks |
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