Tag Archives: deep draw stamping

Buying low priced bearing components – “A practice that will come back to haunt you”

The Precision and Quality of Bearing Components are Critical Characteristics Regardless of the Application.

By Anthony Romero – Sales and Applications Engineering Manager

 

George Rusiecki of the former Torrington Co. described drawn-cup needle roller bearings (NRB) this way:

“For ease of handling and installation, drawn-cup needle roller bearings do as well as loose rollers but in a unitized assembly. The outer shell, which serves as the outer raceway, is accurately drawn from low-carbon strip steel and case hardened. No subsequent machining is needed, making this bearing economical. The turned-in lips of the cup provide mechanical retention of a full complement of trunnion-end needle rollers. Also, these lips act as close-fitting shields and help retain lubricant and exclude foreign matter.

Full-complement drawn-cup needle bearing load ratings equal or exceed those of ball and roller bearings of comparable OD. Thin cross sections allow larger shaft diameters on which the bearings operate directly. The large number of contact lines formed by the loaded rollers suits this type well for static, slow rotating, or oscillating conditions. Drawn-cup caged bearings share many characteristics with their full-complement counterparts, such as being well suited for use in housings of low hardness. Though they have less load capacity than full-complement bearings, they are better suited for high speed and shaft misalignment or load deflection.” [1]

The Use of Deep Drawn Bearing Components

The quality and precision of drawn-cup needle roller bearings are critically important, especially when they are used in automotive deep draw applications such as engines, pulley supports, gear pumps, planetary gears, or transmissions. Paying less for lower-cost bearings can seem like a good cost-saving measure. However, when you consider the labor costs charged by auto mechanics and dealerships to replace NRBs, those savings quickly disappear.

In industrial uses, faulty NRBs can affect the reliability of equipment and cause machine downtime and production losses. Additionally, it is easy to imagine the negative impact on customer loyalty when there is a premature bearing failure in consumer goods like washing machines, lawn mowers, snow throwers, and similar products.

Unfortunately, some offshore factories frequently leverage a higher quantity to make a profit when manufacturing these bearings. With rising material and labor costs in the global market, these providers keep prices low by using cheaper materials, performing low-precision manufacturing, and doing a poor job of inspecting finished parts.

As explained in our blog titled “The importance of raw material quality in the deep draw metal process” defects in materials adversely impact the service life of parts. In the case of NRBs, using low-quality materials affects the load stresses on the raceway. Since any tears, porosity, or inclusions in the raw material can hinder the integrity of the bearing causing a premature failure.

PMP QA Manager inspecting drawn cups

The uniformity of the wall thickness on the drawn cup is another characteristic that plays an important role in maintaining a uniform loading profile on the bearing. At Prospect Machine Products, special inspection procedures are used to ensure that this characteristic is maintained within print specifications.

The same is true of the taper of the cup, since it is also involved in the loading of the rollers. Additionally, the surface finish of the actual internal raceway is crucial to the life expectancy of the bearing due to the thin oil film thickness between the raceway and needle rollers during operation.

Ultimately, there are many characteristics of drawn-cup needle roller bearings that can lead to premature failure when inadequate materials, forming processes, or inspection procedures are used. Buying low-priced bearing components can definitely come back to haunt you!

Ask Us About Your Bearing Project

Have a bearing 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.

 

 

[1] Machine Design – Needle roller bearings: what they are; where they go; why you may need them.  George Rusiecki of the Torrington Co. | Jun 01, 2000

 

How Prospect Machine Products Maintains High OEE and Customer Satisfaction

Overall Equipment Effectiveness – OEE for Deep Draw Stamping

By Anthony Romero – Sales and Applications Engineer Manager.

The universal equation for success in manufacturing, regardless of the product, business model, market segment, or geographical location, is:

(A) x (P) x (Q) = OEE

Where (A) = Availability

             (P) = Performance

             (Q) = Quality

Availability: A high score of a 100 percent means that the manufacturing process (including equipment, gauges, and personnel) is always operating according to the planned production or scheduled time.

Performance: This is where our team optimizes the cycle time. A performance figure of 100 percent means that the press is running as fast as possible and that there are only negligible brief stops for tool maintenance.

Quality: A high score of 100 percent here means that only parts that meet specifications are manufactured. No defective parts are produced and no time-consuming rework is required.

deep drawn metal OEEFocusing on OEE at All Levels

The production team at Prospect Machine Products (PMP) executes a number of daily and weekly tasks to continually improve on our OEE. However, this isn’t strictly a production issue. Our management team meets monthly to ensure that all parameters are positively impacting OEE and we are moving toward our goal of 100 percent for every job.

Steps PMP Takes to Maximize OEE

Preventive maintenance is one of the key parameters monitored by our production team, since an unplanned equipment breakdown can adversely affect delivery times and generate production losses. We also closely monitor equipment health and condition to ensure we achieve the highest possible productivity rates. To support a smooth “running” mode, we carefully train our personnel and ensure the availability of all the tools and gauges necessary for each job.

Our toolmakers also set the press to the highest possible speed (strokes/min) to get the maximum achievable output for our deep drawn metal stampings. In addition, the selection of tools, materials and designs for a job are made with a focus on minimizing the number of stops for deep draw tool maintenance. All of these efforts come together to produce a high first pass yield, which is another key performance indicator (KPIs) we measure.

(Above: PMP’s president Richard Laurenzi going over production KPI’s that impact OEE)

Careful Process Assessment from Start to Finish

To confirm that the steps we take on the front end to ensure high OEE are effective, production and quality assurance personnel monitor defective PPM (parts per million) and scrap rates for all products and machines. They then report any instance where production issues exceed the limits we have set so that a root cause investigation can be conducted and corrective action/preventative action (CAPA) can be initiated.

Top-of-the-Line Deep Drawn Metal Services

All these efforts are made to ensure that we meet customer needs and avoid any interruptions in scheduled deliveries. Ultimately, our OEE initiatives produce a positive impact on on-time delivery and manufacturing costs.

Have a project where the timeliness, quality, and affordability of components is critical?  We’re happy to talk with you about how PMP monitors OEE to deliver the parts you need and the value you want.

Contact us online, email: Info@pmpdeepdraw.com, or call Tony Romero at 203-758-4448 X25

Gemba at PMP – A Powerful Tool for Delivering Customer Satisfaction

By Anthony Romero (Sales and Applications Engineering Mgr.)

Improving the Deep Draw Stamping Process

Gemba is a Japanese term meaning the “real or actual place.” As a preferred deep draw metal stamping company that values efficiency, productivity, and customer satisfaction, Prospect Machine Products (PMP) uses this approach of focusing on the real issues that are impacting the company’s day-to-day operations to promote excellence in the workplace. It is a daily opportunity for PMP leadership to gain valuable insight into the manufacturing process and to identify what ISO 9001:2015 refers to as “opportunities for improvement” (OFIs).

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