Seamless End-to-End Manufacturing Management

Client: A leading energy industry manufacturer in the USA

Part: High-Precision Heat Exchanger Plates (Titanium Grade 2)

Challenge: The energy manufacturer faced significant challenges in producing high-precision heat exchanger plates made from Titanium Grade 2. The production process was fragmented, leading to frequent delays, high scrap rates, and increased costs. Titanium Grade 2, known for its excellent corrosion resistance and strength, posed difficulties in machining due to its toughness and the stringent requirements for precision and surface finish.

Solution: HanaV Manufacturing implemented an integrated manufacturing management system to optimize the production of heat exchanger plates. This solution focused on enhancing machining processes, improving precision, and ensuring seamless coordination between production stages. Key components of the solution included advanced machining technologies, real-time monitoring, and lean manufacturing principles.

Technical Achievements:

• Manufacturing Efficiency: Production cycle time reduced by 40%.
• Cost Reduction: Manufacturing costs decreased by 25%.
• Reliability: On-time delivery rate improved to 95%.
• Quality Control: Defect rate reduced from 5% to 0.5%.

Details:

Part Challenge:

The heat exchanger plates made from Titanium Grade 2 required:

• Exacting Tolerances: The plates needed to meet tight tolerances (±0.1 mm) to ensure proper fit and function in heat exchangers used in critical energy applications.
• Exceptional Surface Finish: A smooth surface finish (Ra 0.3 µm) was necessary to prevent fouling and ensure efficient thermal transfer.
• Complex Machining Stages: The production process involved several intricate stages:
  
  • Forging: Initial shaping of the Titanium Grade 2 billets.
  • Rough Machining: Removal of excess material to form the basic plate shape.
  • Heat Treatment: Enhancing the material properties for improved performance.
  • Finish Machining: Achieving precise dimensions and surface finish.
  • Surface Treatment: Applying coatings or treatments for additional protection against corrosion.

Implementation Steps:

Advanced Machining Technologies: HanaV Manufacturing introduced advanced machining technologies to address the complexities of machining Titanium Grade 2.

• Multi-Axis CNC Machines: State-of-the-art multi-axis CNC machines were employed to handle the precision requirements and complex geometries of the heat exchanger plates.
• High-Speed Spindles and Specialized Tools: High-speed spindles and specialized cutting tools were used to manage the heat and wear associated with machining Titanium Grade 2.
• Advanced Coolant Systems: Enhanced coolant systems were implemented to maintain optimal temperatures and extend tool life.

Precision Machining: The use of multi-axis CNC machines improved machining accuracy and efficiency.

• Complex Cutting Paths: The CNC machines allowed for intricate cutting paths, reducing the need for multiple setups and improving dimensional accuracy.
• Tool Life Management: Advanced cutting tools with coatings were used to extend tool life and maintain performance on Titanium Grade 2.

Real-Time Monitoring and Control: Real-time monitoring systems were integrated to optimize the machining process.

• Sensor Integration: Sensors monitored key parameters such as cutting forces, temperature, and vibration to ensure process stability and quality.
• Data Analysis: Data from sensors was analyzed to optimize cutting parameters, reduce tool wear, and enhance surface finish.
• Immediate Corrective Actions: Real-time monitoring allowed for immediate detection of deviations and corrective actions, preventing defects before they occurred.

Lean Manufacturing Principles: Lean principles were applied to streamline workflows and reduce waste.

• Value Stream Mapping: The entire production process was mapped to identify and eliminate non-value-added activities, improving efficiency.
• Continuous Improvement: A culture of continuous improvement was fostered, encouraging operators to suggest and implement process enhancements.

Seamless Coordination: Ensuring smooth transitions between production stages was critical.

• Integrated Workflow System: An integrated workflow system managed transitions between forging, machining, heat treatment, and surface treatment, minimizing delays and ensuring smooth handoffs.
• Standard Operating Procedures (SOPs): SOPs were developed for each stage to ensure consistency and reduce variability.

Impact on Business:

Manufacturing Efficiency: The adoption of advanced machining technologies and optimized workflows led to a 40% reduction in production cycle time. This improvement allowed the manufacturer to meet production targets more consistently and reduce lead times.

Cost Reduction: Lean manufacturing principles, combined with reduced tool wear and scrap rates, resulted in a 25% decrease in overall manufacturing costs. These savings were passed on to clients, enhancing the manufacturer’s competitive edge.

Reliability: Improved process stability and coordination between production stages increased the on-time delivery rate to 95%. This reliability strengthened the manufacturer’s reputation and fostered stronger customer relationships.

Quality Control: Enhanced precision machining and real-time monitoring significantly reduced the defect rate from 5% to 0.5%. This improvement in quality ensured that the heat exchanger plates met rigorous industry standards, reducing rework and scrap costs.

Conclusion:

HanaV Manufacturing’s integrated manufacturing management system transformed the production of high-precision heat exchanger plates for the energy industry. By implementing advanced machining technologies, real-time monitoring, and lean manufacturing principles, HanaV achieved substantial improvements in efficiency, cost, reliability, and quality. This comprehensive approach not only streamlined the manufacturing process but also set a new standard for excellence in producing critical components for the energy sector.