A major overhaul of existing equipment: A case study pushing the limits of PEEK resin processing.

overview

In the mass production of PEEK resin washers, we reviewed our equipment, molds, and processing conditions as a whole to improve burr defects and increase production capacity.

Because general-purpose machining centers had limitations in achieving both quality and productivity, we extensively modified our existing equipment into specialized machining centers. Furthermore, we designed new molds to achieve high-precision machining.

By optimizing equipment, molds, and processing conditions, we were able to triple production speed while suppressing burr formation. This is a processing example that has maintained a stable supply for over 20 years.

We want to increase production, but the quality isn't consistent!

Orders, which initially amounted to 600,000 units per month, eventually grew to a scale of 2 million units.

While customer expectations were rising, other challenges were becoming increasingly significant on the ground.

PEEK resin has high heat resistance and strength, but it is also a difficult material to process because it is very tough and prone to burr formation.

The general-purpose machining centers we were using at the time had large strokes, making it difficult to maintain consistent quality due to positional errors during machining.

Adjusting processing conditions alone has its limits. Finally, a major decision is needed.

A major decision to balance quality and mass production.

Sales representative T received a request from a customer to increase production.

"We want to meet this production volume without compromising quality."

Engineer T, having understood their feelings, determined that there were limitations to what could be achieved solely through processing conditions.

[The First Challenge] Is there no going back if we fail? A decision that puts quality and productivity at stake.

The solution we chose was to modify our existing equipment into a processing machine specifically for this product.

You may lose the warranty from the press machine manufacturer.

There's no guarantee that modifications will result in the desired performance.

Nevertheless, in order to achieve quality and productivity, we made a major decision and began production.

Although we had never modified equipment before, we transformed the existing equipment into a dedicated processing machine while calculating the gear sizes and proceeding with the design and manufacture of the necessary parts.

[Second Challenge] It doesn't end with just modifying the equipment. We'll also be scrutinizing the molds and processing conditions.

To maximize the performance of the equipment, the molds were also completely redesigned.

We optimized each processing condition individually and built a production line that enables high-precision machining with small strokes.

As a result, we significantly reduced the occurrence of burrs while increasing production speed to approximately three times that of conventional methods.

One attempt has supported a stable supply that has continued for over 20 years.

Sales representative T took action to keep his promise to the customer, and engineer T overcame the risks to make this custom equipment a reality.

That first unit continues to operate as a main piece of equipment.

By comprehensively reviewing equipment, molds, and processing conditions, we achieved both quality and productivity.

For over 20 years, we have maintained a stable supply system, which has earned us the trust of our customers.

We create solutions together with our customers.

Generally, making significant modifications to production equipment involves risks to manufacturer warranties and performance.

However, if it's a truly necessary solution, we won't be bound by existing methods.

We broaden our perspective to include equipment, molds, and processing conditions, and work together with our customers to find the optimal solution.

That's Yamada Manufacturing's approach to manufacturing.

We don't just focus on individual components; we address the challenges that lie beyond them.

We work with our customers to develop the optimal manufacturing process, starting from a single drawing.

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