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Center / Industry News
Leinweber Maschinen Offers Revolutionary ‘New’ Disc Brake Process
Get Connected to the Friction Material Industry In The News 17th February 2004 - Leinweber Maschinen Offers Revolutionary ‘New’ Disc Brake Process The “Compact (C) – Series” Manufacturing System Focus is on “TOTAL PROCESS OPTIMIZATION!” Following many years of analysis and development work Leinweber Maschinen now has available, and in production, a revolutionary, new manufacturing process. Automation is combined with some simple manual integration to make a reliable plus efficient disc brake manufacturing process. The General Manger of Leinweber USA, John Lee, said “This new “C-Series” process implements many aspects of the Toyota Manufacturing System, called Lean Manufacturing. The layout is designed to reduce operator motion and eliminate work in process inventory. Processing is optimized as hot pressed parts are made close to final grind thickness with chamfers and slots molded in. This molding of shapes is already being done in some OEM applications. Part quality is constantly monitored by checking pressing parameters many times a second and comparing final part thickness in the mold die cavity with specified parameters before cycle completes. Energy is saved and oven cure time is optimized as parts are directly transferred “hot” into a continuous flow oven. Finish grind and powder painting are integrated allowing product to flow continuously to the hardware attachment and packaging operation. Leinweber has even eliminated the need for a powder paint gun. Throughout the system, from start to finish, both Productivity and Flexibility are realized. Up to 8 reference numbers can be processed at the same time without any tool change required at a maximum production rate of 8 parts per minute per line. In the VAT (value add time) measurement system we are over 70%. But we did not stop there. With our new Leinweber Logics Division, we also made additional efficiencies available for the Friction Manufacturer’s Administrative Departments. Software options can be purchased to support automating electronic order entry, scheduling production, predicting next tool change time to the minute, notifying other factory support groups that backplates and hardware will be needed at a specific time at a specific machine, and tracking of order status. Just this January we brought to market an optional machine process analysis program that continually monitors automatic machine movements. When any motion or function is not optimized an alarm is generated and a technician is dispatched to return the process to its most optimized status.” Johann Leinweber, President of Leinweber Maschinen said, “When Customers spend money on new machinery they have a right to know their total process is fully optimized – 24 hours of the day. This makes the return on investment happen as planned!” Summary Process Overview Hot Press Modules >>> Post Oven Cure >>> Grind, Powder Paint, IR Cure >>> Post Oven Cure >>> Grind, Powder Paint, IR Cure Total Process time less than 2 hours typical < -----------------------------------------------------------------------------------------------------------------> Measurements - about 18 by 20 meters (60 by 65 feet) Some Key Features of this Layout: 1) OEM or AM System production 2) 16 references possible at same time 3) High temperature post oven cure up to 350°C 4) Fast tool changes on press 5) Typical 3 Operators + logistic support 6) Max. output 16 ppm at 100% 7) Annual output - submit samples to evaluate your formula cure time! * Look at the possible benefits of the Leinweber "C-Series" System ° No high defect rates. Hot pressing uses Leinweber’s precision molding and in mold cavity thickness check before end of pressing cycle. ° No design waste (like flash mold allowance) built into the part weight. ° No waste from slot or chamfer grinding. Slots and chamfers are molded in (even in some OEM applications) ° No excess surface grinding allowance. Molding close to finished thickness possible. ° No grinding material loss. Small quantity of surface grind dust allows reclaim. ° No ‘make up’ outside air for dust collection required if recommended dust collector used. ° No more lengthy tool change times. Hot press tool change time less than 15 minutes for 4 tool sets, preheated, and running again*. ° No tool change time ‘delay’ for finishing. ° No heat up time for post oven curing product. Hot parts input direct from hot press into oven ° No uneven oven curing of inside and outside parts in baskets. “One piece flow” cures all parts fast with same temperature. ° No powder paint gun required. No gun repairs. No gun spare parts. ° No Inventory for Work In Process (WIP). No containers for storage of inventory ° No forklift transport required. No forklift maintenance ° No factory floor space required between processes for forklift roads or Work In Process storage ° No process Delay. Product moves constantly through the process from beginning to end. ° No large dust collectors required. (Only collect from scales and 1 grind stone) ° No specific physical requirements (strength) for operators. ° No manual floor level scheduling required** ° No progress people required to track orders** ° No manual scheduling of tool change, back plate preparation, or hardware delivery to production line** ° No manual input of orders from Customers**. (*) To realize full benefits Customer personnel will receive full training and become proficient in system operation (**) Not required if software options purchased . . Let Leinweber Maschinen Test Your Formula ! . Send sample mix for testing -or- Contact Leinweber to schedule your visit to Leinweber Maschinen Contact Information Austrian Factory USA - Sales Office USA - Service Office Johann-Giefing-Strasse 8-10 Phone: +1 (843) 795.2673 125 Ashley Phosphate Rd. Ste 117 A-2700 Wiener Neustadt, Austia Alt Phone: +1 (843) 767.9543 North Charleston, SC 29418 Main Phone: +43 (2622) 307-0* Fax: +1 (843) 767.9544 Phone: +1 (843) 767.9543 Sales Phone: +43 (2622) 307-136 Email: lwmus3@charleston.net Fax: =1 (843) 767.9544 Fax: +43 (2622) 307-222 . .Email: office.usa@leinweber.at. Email: office.austria@leinweber.at . . . . . For more information visit Leinweber on ifriction.com Click << Leinweber Maschinen >> Here . or visit their website at: www.leinweber.at Source: Leinweber Maschinen GmbH Press Release
Leinweber Maschinen GmbH Press Release - Feburary 17, 2004 |
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