Ajax Manufacturing Company Case Study Solution

HVAC Mass Volume Header Plate

by ejajax | Nov 30, 2017 | Case Studies

When a long-standing HVAC client modified a large component to improve performance, they came to Ajax for help in the fabrication. A critical link in a long supply chain, the 43-inch precision sheet metal part includes 5 compound bends.Quality problems would shut down the production line. We provide 20,000 high-quality pieces per year.

Product DescriptionHVAC Mass Volume Header Plate
Capabilities and ProcessesTurret Press Blanking; Compound Forming; Prototyping; PPAP; SVPP; Custom Kit Packaging
Tightest Tolerance.003 inch hole diameter; 1 deg forming
Material Thickness.080
Material Used5052 H32 Aluminum
Industry for UseHVAC
Volume20K annualy
Lead TimeKANBAN
Delivery LocationOffshore
Standards MetRoHS; REACH
Product NameHVAC Header Plate
Project ScopeManufacture 43-inch long part that includes 5 compound bends

Mass Volume Large HVAC Component

by ejajax | May 11, 2015 | Case Studies

When a long-standing HVAC client modified a large component to improve performance, they came to Ajax for help in the fabrication. A critical link in a long supply chain, the 43-inch precision sheet metal part includes 5 compound bends.Quality problems would shut down the production line. We provide 20,000 high-quality pieces per year.

Product DescriptionHVAC Mass Volume Header Plate
Capabilities and ProcessesTurret Press Blanking; Compound Forming; Prototyping; PPAP; SVPP; Custom Kit Packaging
Tightest Tolerance.003 inch hole diameter; 1 deg forming
Material Thickness.080
Material Used5052 H32 Aluminum
Industry for UseHVAC
Volume20K annualy
Lead TimeKANBAN
Delivery LocationOffshore
Standards MetRoHS; REACH
Product NameHVAC Header Plate
Project ScopeManufacture 43-inch long part that includes 5 compound bends

Solenoid Shell – Progressive Stamping Electric Motor Casing

by ejajax | May 11, 2015 | Case Studies

Our client relies on Ajax to provide just-in-time inventory to its offshore manufacturing facility, without resorting to expensive air shipments or jeopardizing a complex supply chain. In addition to providing cost-effective inventory management, we devised a three-hit punch press operation to replace the drawn over mandrel (DOM) tubing the client previously used. The redesign saved more than $1.00 per part.

Product DescriptionElectric Motor Solenoid Casing
Capabilities Applied/ProcessesProgressive stampingcustom packaging
Tightest Tolerance.005 inch (Hole Diameter)
Material Thickness10 GA (.134")
Material UsedHRPO Steel
Material FinishZinc and yellow plating
Industry for UseRefrigeration
Volume75K annually
Lead TimeKanban
Delivery LocationkOffshore/Caribbean
Standards MetCustomer supplied print and solid model
Product NameSolenoid Shell
Project ScopeRe-engineered from DOM to progressive stamping. Custom cell packaging.

Curved Architectural Framing

by ejajax | May 11, 2015 | Case Studies

Applying Lean Principles to a new customer’s precision stamping challenge, Ajax reduced production time from a month to a single day. Orders placed by 11:00 a.m. are manufactured, packaged and shipped by 5:00 p.m.While quantity of production for the progressive die stamping has grown to meet the customer’s increasing market share, quality has remained at 99.9%.

Radius Track

“Ajax doesn’t start to produce the product until they get the order. All non-value-added lead time and inventory have been completely eliminated,” said the president of Radius Track. “It has helped us to manage business issues like capacity, storage, and human resources. Our cash flow is not tied up storing finished goods. That’s a huge business advantage.”

Product DescriptionPrecision Progressive Die Architectural Component
Capabilities and ProcessesTooling Design; Prototyping; Progressive Stamping; Custom Packaging
Tightest Tolerance.005 inch Hole Diameter
Material Thickness20 GA (.036 inch)
Material UsedG60 Galvanized
Material FinishUnfinished
Industry for UseArchitectural Construction
Volume30K annualy
Lead TimeSame Day
Delivery LocationUSA (multiple destinations)
Standards MetLEED
Product NameCurved Large Component Architectural Framing
Project ScopeRedesign Process Flow to Reduce Production Time; Labor and Inventory

Appliance Door Hinge

by ejajax | May 11, 2015 | Case Studies

Our client is saving more than $250,000 a year since Ajax took over the manufacture of this bottom hinge almost 20 years ago. Our continuous improvements in materials selection, tooling and production automation have eliminated heat treating, deburring and manual pin insertion.We achieved fully automated assembly with 0 PPM field failure.

Product DescriptionMass volume appliance hinge with progressive die stamping
Capabilities AppliedProcesses;Design; prototyping; pin insertion done in progressive stamping die
Tightest Tolerance.003 (Hole diameter)
Material Thickness10 GA (.135")
Material UsedGrade 50 HSLA/HRPO
Material FinishZinc and clear (RoHS compliant)
Industry for UseAppliance
Volume800K annualy
Lead Time1-3 days
Delivery LocationMidwest U.S.
Standards MetRoHS
Product NameAppliance door bottom hinge
Project ScopeReduce material gauge and increase strength for piece part cost reduction.
Design WorkMaterial selection; tooling re-design

The Black Box Mystery Fabrication Project

by ejajax | May 11, 2015 | Case Studies

When our customer saw our redesign, which cut their part cost nearly in half, they immediately said yes–and swore us to secrecy. That’s why you won’t see a photo or product description here.

Beginning with a 22 gauge component that the customer was post-painting, we value-engineered a new, one-piece design with a proprietary forming and fastening system that eliminated welds. The new design enabled gauge reduction to 24, a one-pound weight reduction per part. A pre-painted finish eliminated powder coating. The product, completed in a single work cell with fewer steps, added $200,000 a year to the customer’s bottom line.

Product DescriptionBlack Box Capabilities Applied/Processes; Engineer; design; prototype; custom equipment and tooling
Tightest Tolerance.005" (Hole Diameter)
Material Thickness.050"24 GA(.023")
Material UsedPre-painted G40 Galvanized
Material FinishN/A
Industry for UseCommercial Construction
Volume60000 annual
Lead TimeSame day
Delivery LocationMidwest
Standards MetLEED
Product NameBlack Box
Project ScopeReduced material gauge; eliminated welding; eliminated painting; developed work-flow center to reduce inventory and labor
Design WorkMaterial selection; custom equipment and tooling; manufacturing design

Client Branach

Location Melbourne, Australia

Branach Manufacturing is perhaps the best Lean Transformation we have seen in a Small or Medium Sized Enterprise (SME). Branach have driven rapid growth through outstanding customer service and value delivered through a world class Lean production system. In this TXM video, TXM Managing Director, Tim McLean interviews Branach founder, Mike Walsh talks about their Lean journey and what it has meant for his business.

Read the Branach Case Study

Branach Manufacturing is perhaps the best Lean Transformation we have seen in a Small or Medium Sized Enterprise (SME). Branach have driven rapid growth through outstanding customer service and value delivered through a world class Lean production system. In this TXM video, TXM Managing Director, Tim McLean interviews Branach founder, Mike Walsh talks about their Lean journey and what it has meant for his business.

Find out more at https://txm.com.au/video/txm-video-lean-case-study-branach-manufacturing

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