August 9, 1999
STAMPING PROCESS MAINTAINS QUALITY WITH QUICKER TURN AROUND TIME AND LOWER COST

JADE developed the process for a leading manufacturer of electrical boxes and fittings. The manufacturer wanted to create a superior EMT fitting while reducing unit cost. Initially under development by the customer, JADE was contacted when they were ready to abandon the project after 18 months of failing to meet strict UL standards. JADE analyzed and reviewed the existing processes, and in less than a year, developed a solution that not only reduced stamping cost, but produced a superior product. JADE’s collaboration with the customer included design, analysis and product support.

Developing the new process presented several special challenges. EMT fittings, used in most circuit boxes in homes and businesses, must meet strict UL standards. The manufacturer was having difficulty meeting these standards and running at the desired speed of 60-100 strokes per minute. In addition, as drawn metal generates a lot of heat, the parts were generating steam and breaking down the coolant.

Using flat stock that is deep drawn in a transfer tool, JADE met UL standards, reduced the production cost from $.15 to $.05 per part, produced a better looking fitting and improved the functional working of the piece. The traditional process of forming the piece out of tube stock resulted in a part that was easily stripped when a hex nut was screwed into it. The flat stock piece allows a stronger hex and is cool to the touch, eliminating the need for cool down that resulted from the old process.

The improved appearance, reliability, and cost reduction satisfied all of the customer’s needs. JADE is currently working on additional process improvements to further reduce the per fitting unit cost.

Supporting a mixture of new and old technologies with a wide range of requirements, many existing stamping operations have manual, outdated, or inefficient steps and processes. These processes invite reexamination. Automating manual procedures and identifying process modifications can reduce cost and turnaround time.

Customers in a variety of industries seek out companies that can provide end-to-end service and innovative solutions. They want a provider that not only meets their requirements, but helps to keep costs down, eliminates duplicate work, and creates the high-quality products and services their industry demands. The JADE Corporation focuses on developing these high quality, economic solutions.

Similar process evaluations can benefit many of the industries served by the precision stamping market. Industries, including computer, electronics, medical, telecommunications, automotive and more, can reap the benefits of these lower cost, high quality solutions.