Product category:
Power presses, hydraulic
News Release from: AP and T AB, Automation, Press and Tooling | Subject: LMB 4000kN (450 US tonf) hydraulic press and line
Edited by the Manufacturingtalk Editorial
Team on 07 September 2005
Press system automates wheel rim
production
An automated production line for the manufacturing of automotive wheel rims, and based on a hydraulic press, has cut raw material costs and reduced in-process inventory.
When the Kawasaki plant in Lincoln, NE decided to invest in a fully automated production line for the manufacturing of ATV wheels, AP and T was the logical choice The implementation of two new press lines designed and manufactured by AP and T has met and exceeded their expectations
This article was originally published on Manufacturingtalk on 5 Sep 2005 at 8.00am (UK)
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Kawasaki Motors Manufacturing (KMM) in Lincoln, Nebraska produces a wide variety of vehicles which are sold world wide, including motorcycles, Jet Skis, ATVs (All Terrain Vehicles) and MUVs (Mule Utility Vehicles).
KMM is also the largest manufacturer and supplier of ATV wheels.
In 2004, the Lincoln plant produced an impressive 2.1 million ATV wheels.
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The plant employs more than 1,800 people, making Kawasaki one of the largest employers in Lincoln.
In 2001, the company decided to dramatically revamp its production of wheel rims.
Until then, a large part of the production had been dependent on manual labor.
As per Tobin Watson, project manager for the installation at Kawasaki, providing a safer work environment and a more efficient process was the goal.
The time had come to automate the operations.
Two press lines Kawasaki needed a supplier who could deliver two complete press lines.
The first press line would be used for making round and rectangular blanks directly from coil, and the other would then turn the round blanks into finished rims.
As simple as this might seem, consider that Kawasaki's production encompasses a wide variety of wheel sizes and designs using over 60 different existing dies in the process.
Kawasaki wanted the supplier of the lines to provide a complete solution, which AP and T was more than capable of.
AP and T's motto is 'One Responsible Partner' and according to Watson, AP and T has proven it by delivering the complete package.
Many new benefits The AP and T coil blanking line includes a coil feed system along with a model LMB 4000kN (450 US tonf) hydraulic press, a blanking die and a stacking system for the blanks with a production rate of up to 60 blanks/min.
The line was placed into production in September 2002.
As a result, KMM has been able to cut their raw material costs and reduce their in-process inventory.
But even more benefits were realized in September 2003 when the new AP and T five press, fully automated forming line went into production.
In addition to improving plant safety, the implementation of the line yielded even more cost savings and accelerated production rates.
A closer look The fully automated production process is quite impressive.
The stacked blank produced in the blanking line is transported in pallets to the start of the forming line.
At the end of the line, the finished rims are palletized and staged for transportation.
No manual labor is required during the entire process.
The forming line consists of five AP and T ZL presses equipped with hydraulic die cushions and ejector cylinders.
Each machine has a press force of 2500kN (280 US tonf).
AP and T's automation consists of six CD25 robots for loading, unloading, and press-to-press transfer.
The line controls consist of AP and T's MC32 programmable control system, which allows the operator full control over the line.
The production line process requires very little manual labor.
Just one operator is needed to monitor the line and perform quality checks.
Additional features AP and T offers many technologically advanced solutions.
One of these solutions is a multi function bar code system.
At the front of the line, sensors read the bar code on incoming pallets in order to verify that the correct blanks are being loaded.
At the rear of the line, production control information is printed on new bar code stickers that are attached to the pallets of finished disks.
Other impressive features are the automatic tool clamping and integrated die identification.
This eliminates the risk of running the wrong die combination or false die positioning.
The system is easy to operate and has reduced lead times, tooling costs and tool repair costs for Kawasaki.
Heavy usage The new AP and T line has proven to be extremely reliable for Kawasaki and continues to play an important role in overall production at the Lincoln plant.
Today, the line is booked at 80 percent of its current capacity during all three shifts with higher production needs expected.
According to Watson, Kawasaki expects production demands will have the line operating at 90 percent capacity, seven days a week with continuous operation.
An extremely capable company Tobin Watson describes the project at Kawasaki's Lincoln plant as a success.
His experience working with AP and T has been very positive, and he remains very satisfied with the response he receives when ordering spare parts, service or support.
He explained that he has been able to solve most problems with a phone call.
His conclusion is that AP and T has a very customer-caring and project-focused attitude.
In Watson's opinion, AP and T is an extremely capable company.
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