Autocam
Project Title: Grinding Process Solutions
Company Profile: Autocam Corporation specializes in precision-machined parts for customers in the automotive market, handling major projects from start to completion. Founded in 1988, the company has grown rapidly to 2,300 employees in 13 locations through a combination of long-term customer relationships, aggressive marketing, and strategic acquisitions, which include well-established companies in North America, Europe, and South America.
Project: Autocam faced a set of challenges in its centerless grinding operation of components for fuel injectors. Starting with the original setup parameters that had been recommended by the machine manufacturer, Autocam was experiencing an unstable, inefficient, and costly operation to achieve correct-size components for the customer. The inconsistency in the size of the parts from shift-to-shift or day-to-day created significant costs for machine downtime, additional labor for sorting out wrong-size parts, rework to meet delivery numbers of correct-size parts, and the expense of excess scrap. Correct parts per 12-hour shifts were ranging from 30,000 to 90,000 (compared to 182,000 per 24 hours after TechSolve’s changes were made). Despite persistent efforts by Autocam’s operators to find the optimal mix and balance of adjustments that would eliminate the instability, the problems continued to plague the operation.
A TechSolve grinding expert made two three-day visits to the Autocam facility in Kentwood, Michigan, over a period of three months to observe, diagnose, and help implement recommendations. TechSolve’s solutions involved multiple integrated setup parameters and adjustments to the regulating wheel grade, dressing tools, and overhead guide. The TechSolve expert helped Autocam operators identify, integrate, and implement adjustments and changes that helped them consistently produce the desired quantity of fuel injector parts at the correct size, delivered on time.
Results: TechSolve helped lead Autocam to a new production record of 182,000 pieces in 24 hours and to an increase in parts per dress from 30,000 to 72,000, with no overtime required. By considerably improving the operation’s stability, Autocam eliminated the related scrap, re-work, and machine downtime. The net effect of all these changes equated to an overall positive impact to Autocam’s business.
Similar multiple integrated setup parameters and adjustments were made on five other grinding operations, which eliminated fixturing problems and improved productivity greatly
“TechSolve grinding consultants approached our challenge like part of our team. Through their hands-on, logically engineered solutions, TechSolve brought us relief for what had become an overwhelming headache.”
John Giles, Manufacturing Engineer, Autocam
