CASE STUDY Brake Disc Efficiency Breakthrough: A Case Study OBJECTIVE The objective was to develop a grinding solution capable of handling multiple brake disc configurations for commercial motorcycles, with the adaptability for future production needs. The challenge lay in creating a system that could maintain the necessary production strength and performance while incorporating a fully automated cycle. The specific target was to achieve a grinding cycle time of 30 seconds per disc, setting a high bar for both efficiency and flexibility in the manufacturing process. SOLUTION To tackle the pressing need for a flexible and efficient grinding process for various brake disc configurations, the solution implemented involved engineering a bespoke Vertical Double Disc Grinding Machine. This machine was not only tailored to the current requirements but also built with the foresight for easy reconfiguration in response to future demands or design updates for the brake discs. The customization extended to incorporating an automatic load, unload, dry, and stack system aimed at streamlining the production flow and maximizing output. The comprehensive design of the system brought together state-of-the-art grinding technology with the necessary safety features and a custom program tailored to optimize cycle times. This approach holistically addressed the client’s demand for a sub-30-second grinding cycle while ensuring the machine’s adaptability for subsequent modifications. As a result of this strategic engineering solution, the company was poised to enhance production rates to unprecedented levels, demonstrating the value of a solution that harmonizes flexibility with efficiency. Key Results The custom-engineered Vertical Double Disc Grinding Machine delivered a transformative impact on the client’s production capabilities. Key results included meeting the ambitious target of a 30-second grinding cycle, which significantly accelerated production times and increased the output rate to the highest in the company’s history. The integration of advanced safety features and optimization programs further streamlined the manufacturing process, achieving an ideal balance of speed, safety, and adaptability in production. Contact Us To Know More About This Case Study, Talk To Us. Send Message
CASE STUDY Precision and Efficiency in Roller Ring Production OBJECTIVE The client wished to achieve a balance between precision and efficiency in grinding operations for roller rings. The engineering challenge was to reach precise tolerances in parallelism, flatness, and surface finish to comply with stringent global quality standards, while also enhancing the production rate, thus reducing cycle times without quality compromise. SOLUTION Alex Machine Tools provided the Double Disk Grinding solution with a fully automated Grind Cycle – Automatic loading, post process gaging right after the job left the grinding wheel, automated unload with poke yoke error proofing. Double disk grinding simultaneously removed material from both sides of the rollers. Our machines are designed to be able to carry the rollers in such a manner through the grinding wheels that achieves the desired finish, pattern, parallelism and flatness desired. This is our strength. Machine design for process optimization and part success. Process Capability was maximized through our innovative method of post process gaging at the machine out put itself. This combined with a fully automated dress cycle, leaves no room for operator error or invention, maximizing cycle time. Key Results Excellent finish, desires results, a very tight band of size tolerance – overall a robust grinding solution providing accuracy, reliability and precision. Contact Us To Know More About This Case Study, Talk To Us. Send Message
CASE STUDY Complete Automation of the Face Grinding Cycle OBJECTIVE TVS Motor is the third largest two-wheeler manufacturer in India, with an annual production capacity of 3.2 million 2 wheelers & 1.2 Lakh 3 wheelers. In the automobile industry cycle time, consistency within the grinding cycle and accuracy over time is critical. The Goal was to minimize Cycle time, improve Predictability Consistence of Process. Manual load, unload and measuring of the Connecting Rods was time consuming, un predictable, off-line and operator dependent. SOLUTION A Double Disk Grinding solution with a fully automated Grind Cycle – Robotic loading, post process gaging right after the job left the grinding wheel, automated unload with poke yoke error proofing was designed and executed. Double disk grinding simultaneously removes material from both sides of the connecting rod at unbelievable rates of production. A plunge cycle gives TVS Motors the option to grind the job in one pass, hence handling the job only one time. At Alex Machine Tools, we provide simple solutions to demanding and complex problems. With Customized back-end programming, clever designs and ergonomic operating arrangements, our machines are designed to maximize production and precision. We design our machines with the Operator and Process in mind. Key Results The result was a process with results in a very close tolerance band due to the immediate check and balance of wheel wear through the automatic gaging system, minimal dependability on the operator through automation, a fast cycle, high accuracy through ALEX Double Disk grinding – overall a robust grinding solution providing accuracy, reliability and precision. For more information on accuracies and cycle time achieved, please contact us. Contact Us To Know More About this Case Study, Talk To Us. Send Message
+91 7045291771
022 67425121 / 122 / 123
8, Gaiwadi Industrial Estate, SV Rd, Goregaon West, Mumbai: 400062.
+91 7045291771
022 67425121 / 122 / 123
Copyright © 2024 Alex Machine Tools. All Rights Reserved. | Privacy Policy | Terms & Conditions | Disclaimer | FAQs
Vernon Pontes, an engineering graduate from University of Texas, ran and grew several business in USA very successfully. He founded and grew through organic growth and acquisition the Energy Products Group within Dover Corporation and sat on the Board of Dover Resources for several years. Since then, Vernon has turned around businesses for Private Equity Companies as a next step in his Career.
Vernon now runs a successful Components Division for the Alex Group as well as brings a rich Finance Business and Operations focus to Alex Machine Tools.
Nisha Lobo, graduated with a mechanical engineering degree from Cornell University. As President of Texas Hydraulics, USA, Nisha grew the Company, created a Lean culture in the organization and was promoted to Supply Chain Director for the parent Company Dover Corporation responsible for Global Sourcing for the Corporation.
Nisha is now focused on Alex Machine Tools and leads the business with a strong focus on global markets, lean operations and excellent service.
You can see how this popup was set up in our step-by-step guide: https://wppopupmaker.com/guides/auto-opening-announcement-popups/