All posts by Anthony Romero

Convirtiéndose en el contratista de manufacturación preferido para clientes en México. (English version below)

 

Por Anthony Romero – Gerente de Ventas & Aplicaciones de Ingeniería.

PROSPECT MACHINE PRODUCTS (PMP)

30 de septiembre de 2019.

Debido a que no sólo está impulsado por los precios de las materias primas, pero los costos de transporte y la eficiencia de fabricación, así es como el mercado de embutición profunda de estampado metálico está cambiando constantemente. Para garantizar que nuestra empresa está reconociendo y adaptándose a esos cambios, asistimos a una serie de eventos comerciales cada año.

PMP tuvo la oportunidad de viajar a una conferencia de la Asociación de Formación de Metales de Precisión (PMA por sus siglas en inglés) en Querétaro, México el pasado mes de agosto. En este interesante e informativo evento se habló del mantenimiento de prensas, la lubricación, los sistemas integrados, la seguridad de operación y otros temas relacionados con el estampado de metales. Todos los temas fueron presentados por personas altamente calificadas en el campo como Bob Braswell (Consultamex), David Lara (Flex Systems) y Pedro Martínez (Tower Metalworking) por solo mencionar algunos de ellos.

Sin embargo, las sesiones sociales para el establecimiento de contactos (networking) también fueron muy importantes. En esas interacciones se hizo evidente el alto grado de sofisticación y atención al detalle de nuestros colegas mexicanos en la industria del estampado de metales.

Conectando con nuestros clientes y prospectos Latinoamericanos

Después de la conferencia, nuestro equipo se embarcó en una gira cubriendo estados en el centro de México, incluyendo Aguascalientes, San Miguel de Allende, San Luis Potosí, y Querétaro, visitando varios clientes y prospectos en la región.  Aunque hay muchas herramientas disponibles para la comunicación digital, no hay nada como conocer a alguien en persona y estrechar la mano. Esa conexión personal es especialmente importante en la cultura Latinoamericana. De hecho, la siguiente cita muestra esta relación:  “En la amistad, al igual que ocurre en los negocios, las relaciones deben reportar beneficios a ambas partes y como sucede en toda vinculación estrecha, implican respeto, confianza y dependencia mutua” (Integración Empresarial – Consultoría)  

Observaciones sobre las necesidades de estampado de metales de embutición profunda en México

Algo que llamó la atención durante nuestros viajes fue la complejidad de geometrías y aleaciones metálicas de alta tecnología diseñadas para el proceso de embutición profunda que fueron puntos de plática con nuestras contrapartes mexicanas.

No hay duda de que nuestros vecinos del sur están diseñando componentes intrincados donde la experiencia y conocimiento técnico de Prospect Machine Products pueden ser muy útiles. Esto se hizo aún más claro durante una sesión de almuerzo con discusión técnica organizado en las facilidades de uno de nuestros clientes donde los miembros del público hicieron muchas preguntas interesantes.

 

 

 

(Foto de izquierda – Presentación técnica de PMP)-San Miguel de Allende – México

 

Relaciones sólidas en toda América del Norte

En PMP, estamos orgullosos de nuestra entrega a tiempo, excelente calidad del producto, soporte de ingeniería, precios competitivos, y lo más importante, la estrecha relación de cliente a proveedor con todos nuestros clientes Norteamericanos, desde Canadá hasta México y en todo Estados Unidos.

¿Tiene un proyecto de estampado metálico de embutición profunda que sería mejor manejado por un proveedor que realmente se preocupa por su éxito? ¡contáctenos! Envíe un correo electrónico Email info@pmpdeepdraw.com o llame al 203-758-4448 X25 para ventas e ingeniería.

Becoming the Contract Manufacturer of Choice for Customers in Mexico

By Anthony Romero – Sales & Applications Engineering Mgr.

Prospect Machine Products

September 30, 2019

Because it’s not only driven by raw material prices, but transportation costs and manufacturing efficiencies as well, the metal stamping deep draw market is constantly changing. To ensure that our company is recognizing and adapting to those changes, we attend a number of trade events each year.

PMP had the opportunity to travel to a Precision Metalforming Association (PMA) conference in Queretaro, Mexico this past August. This interesting and informative event dealt with press maintenance, lubrication, integrated systems, safety, and other issues related to metal stamping. All the topics were addressed by highly knowledgeable people like Bob Braswell (Consultamex), David Lara (Flex Systems), and Pedro Martinez (Tower Metalworking ) to mention just a few.

However, the networking sessions were also very important. In those interactions the degree of sophistication and attention to detail of our Mexican colleagues in the metal stamping industry became evident.

Connecting with Our Latin American Customers and Prospects

After the conference, our team embarked on a tour encompassing several states in Central Mexico including Aguascalientes, San Miguel de Allende, San Luis Potosi, and Queretaro, visiting several customers and prospects in the region. Although there are many tools available for digital communication, there is nothing like meeting someone in person and shaking their hand. That personal connection is especially important in Latin American culture. In fact, the following quote shows this relation: In friendship, as in business, relationships must bring benefits to both parties as happens in all alliances They imply respect, trust and mutual dependence (Quote translated from Integración Empresarial – Consultants)

Observations on Deep Draw Metal Stamping Needs in Mexico

Something that caught our eye during our travels was the variety of complex geometries and engineered high-tech alloys for deep draw that were points of discussion with our Mexican counterparts.

There is no doubt that our neighbors to the south are designing intricate components where the technical know-how of Prospect Machine Products can be helpful. This became even more clear during a lunch-and-learn PMP session and technical discussion that was hosted by one of our customers. Audience members asked many insightful technical questions.

 

 

 

 

(Left photo) PMP’s technical presentation (San Miguel de Allende – Mexico)

Strong Relationships Throughout North America

At PMP, we’re proud of our on-time delivery, excellent product quality, engineering support, competitive pricing, and most importantly, our close customer/supplier relationships with all of our North American customers, from Canada to Mexico and all around the U.S.

Have a deep draw metal stamping project that would be best handled by a provider that truly cares about your success? Contact us! Email info@pmpdeepdraw.com or call 203-758-4448 X25 for sales and engineering.

Operational Excellence at Prospect Machine Products

“An essential key to remain competitive in today’s global marketplace”

By Anthony Romero – August 12, 2019

Sales and Applications Engineering Manager

Prospect Machine Products had the unique opportunity to receive black belt Six Sigma training by a customer with a strong lean manufacturing know-how. In that training, several chosen suppliers from other industries were also certified.

PMP’s Director of Quality Dave Boiano became a Black Belt and has since implemented several continuous improvement initiatives:

  • Gemba daily walks to discuss current manufacturing activities, production planning, and machine Overall Equipment Effectiveness (OEE) – See PMP’s blog May 2019
  • Manufacturing Key Process Indicators (KPIs) that are reviewed monthly by the management team (sales, quality, production planning, and purchasing)
  • Several Kaizen events to eliminate waste and improve efficiency
  • Leadership’s daily involvement on all phases of production
  • Employee participation in lean manufacturing

Our company’s focus on lean and continuous improvement manufacturing has earned us an excellent reputation among our competitors, both in the U.S. and abroad. Our pricing is very competitive based on feedback from established customers and prospects. However, PMP’s quality and on-time delivery are also world-class, achieving high ratings in the market.

And when it comes to new projects, our Advanced Product Quality Planning (APQP) method is another way we ensure customer satisfaction. This process calls for the involvement of toolmakers, quality personnel, manufacturing engineering, production planning, and sales during the launch phase of any new part or product. That involvement helps identify and remove roadblocks that might otherwise impede a project down the road.

A commitment to safety and willingness to absorb the costs associated with it also figure into operational excellence for multiple reasons. First and foremost, nobody wants see employees get injured at work. Plus, no company wants to be faced with the staffing and productivity challenges that arise when a team member is unable to work. That’s why safety is a high priority at PMP. Similarly, environmental compliance is important. Consequently, we have maintenance and engineering personnel who are tasked with ensuring that we are meeting all applicable guidelines in our operations.  

Technical support also plays a role in operational excellence. It must be provided in a timely manner and by individuals who understand both the company’s capabilities and the needs of its clients. This is especially important on new projects but also applies to ongoing projects. We take all the steps necessary to ensure our technical support is unmatched in the industry.

Other Elements of Operational Excellence

In addition to all of the internal factors that support operational excellence, there are external factors that come into play as well. For example, supply chain management is critical. It requires strong relationships with raw material and service providers who share our commitment to quality and on-time delivery, as their efforts affect our customer satisfaction as well

Ultimately, achieving operational excellence is no easy task. It involves every aspect of running a manufacturing business and requires a significant investment of time, effort, and focus. However, we are committed to it and that commitment has proven to be the core of our success at Prospect Machine Products.

Have a deep draw metal stamping project where precision, quality, and on-time delivery are crucial? Contact us! Email info@pmpdeepdraw.com or call 203-758-4448 X25 for sales and engineering

Deep Draw Components in Sealing Technologies

By Richard Laurenzi (President) and Anthony Romero (Sales and Application Engineering Manager) –Prospect Machine Products – July 22, 2019Deep drawn mechanical sealing components

Deep drawn mechanical sealing components is a rapidly growing domestic and international market for us at Prospect Machine Products. PMP customers benefit from our broad deep draw tooling selection, our deep drawing metal forming progression, and our CMM metrology, which have all been keys to our expansion in this market.

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What’s more, our collaborations with customers in the European Union and Asia have led to significant U.S. localization of deep draw sealing components and product lines for the automotive, appliance, outdoor power equipment markets, and more applications.

Through deep drawing, we’re able to add features to sealing components that increase the capability of metal inserts in all forms of seals. Transfer press capabilities that allow us to add features such as small holes, lips, rollovers, dimples, and tapers minimize our customers’ costs and enhance bonding and adhesion of the seal to the insert.

Sealing Applications

Our deep drawn metal stampings for seals can be found in:deep drawn metal stampings for seals

  • Rotational shaft oil seals in gas-powered engines and transmissions
  • Valve stem seals for liquid propane engines
  • Dust and grease seals in tie rod ends, ball joints, and other automotive suspension applications
  • Oil and water pressure seals
  • Oil seals for name-brand home appliances

Deep Draw & Seals – Special Requirements

Deep draw sealing components require precision fits to be suitable for very rugged environments. To that end, we provide the ferritic nitrocarburizing (FNC) heat-treatment process to our customers as an essential value-added service performed by skilled and experienced experts. We also provide real-time SPC data collection, cradle-to-grave traceability, and enhanced capabilities to view and precisely measure very tight dimensions and rollovers without a gap on very small formed parts.

A very critical requirement on some of these seals is the no-gap specification in the roll over of the lip. Otherwise the insert is considered faulty due to the engineering design. This is where the know-how of the toolmakers and engineers becomes paramount, since especial deep draw tool designs are needed. Additionally, the lots are sampled during the production by sectioning several parts and visually ensuring that there is no gap in the rollover under high magnification.

Have a deep draw metal stamping project for a sealing application where precision, quality, and on-time delivery are crucial? Email info@pmpdeepdraw.com or call 203-758-4448 X25 for sales and engineering.

 

Tools for Deep Draw Metal Stamping – Important Facts

Why Tool Design and Maintenance are Critical in Deep Draw Metal Stamping

By Anthony Romero – Sales and Application Engineering Manager

The design of deep draw tooling is based on engineering data, simulation, and external software modified with internal concepts. Some of the items that are considered are work piece material properties, draw reduction ratios, clearances, press speeds, blank holder pressure, and others.

However, there is metal-forming expertise that is involved as well. This is where our toolmakers interact with the assigned engineer to optimize the tooling based on historical data and expert knowledge. As mentioned in our blog on the “importance of mentorship” in our industry, it is crucial for the experienced toolmaker (i.e., the metal-forming expert) to pass their insights on to apprentices in the team. (Check out “The Experts Among Us” by Peter Ulintz in MetalForming magazine, March 2017.)

deep draw tooling

Tool set: punches, dies and fingers needed for deep drawn process.

The Many Tooling Considerations in Deep Draw Manufacturing

tools for deep draw stamping

Dave Boiano – Mfg. Eng / QA Director designing tools needed for the deep drawn process

We take many considerations into account regarding the tooling for our deep drawing applications and projects. For example, the number of stations is based on the draw and complexity of the part. The photo above shows a process that requires 10 stations and the respective punch and die, as well as the fingers that are required to transport the work piece from one station to the other.

Another variable to be considered is the estimated production volume. The material chosen for some of the punches and dies will depend on this volume and the actual load calculated during the deep draw operation. Special coatings or tool steels might also come into play (carbide coatings, A2, or M2 material), depending on the potential volume and high loading.

Taking Responsibility for Tooling

It is important to keep in mind that a reputable deep draw metal stamper like Prospect Machine Products (PMP) assumes all liability for the tooling for the service life of the work piece – potentially several years. This is a critical concept, since tooling costs can be significant. But with PMP, it is a one-time investment.

Offshore competitors understand this barrier to entry, so they amortize the tooling cost on the piece price to soften the initial financial impact. PMP doesn’t use this somewhat deceptive tactic, since the customer might end up paying several times the initial tooling cost when the project or the production part lasts several years.

Tooling Forensics Extends Tool Life

Another place where the toolmaker’s skill and experience are valuable to the customer is in what is referred to as “tooling forensics.” PMP’s toolmakers inspect all tooling for irregular wear, chipping, or other early degradation after the initial runs and setups.

Then, light design modifications and lubrication changes are made to increase the life of the tooling. This important step has a positive impact in keeping lead times short and helping to ensure on-time delivery (OTD).

Have a deep draw metal stamping project where precision, quality, and on-time delivery are crucial? Email info@pmpdeepdraw.com or call 203-758-4448 X25 for sales and engineering.