COMPRESSION SPRING

The Problem

At that time, it was necessary to assemble 32 springs in order to press 16 needles against the retainer with one-way clutch bearings for automobiles. However, the assembly takes a lot of man-hours. The customer was seeking to reduce the man-hours required for the work.

As an operation, since two compression springs of the same shape are assembled per needle, if this push spring is one part connected from the beginning, the assembly can be completed in one operation. Can this not be connected?

The Solution

  • Development Speed
  • Advanced Technological Capabilities to Reduce the Number of Cutting-Edge Equipment Components

Since the machine setter which heard the explanation could not be processed at all by the conventional coiling machine, it was decided to change to the NC multi-forming machine. However, because of the structure of the machining machine, machining is not possible by a series of programs, but by devising such as preparing a sub-program halfway, it was possible to make two springs into a set. As a result, 32 assembly steps were reduced by half to 16 steps, and customer ordering management was also simplified. After 10 years of development, the line became the standard product with 24 hours full operation a month.

Specifications

Product

Compression spring

Forming Method

Numerical control machine

Location

Japan

Customer

Bearing manufacturer

Application

Clutch

Market

Automobiles

Leadtime

3weeks

Purpose

To prevent vibration loosening of nuts

Solution

Advanced equipment, prototyping

Customers Benefit

By converting two parts into one part, the man-hour for assembly is reduced by half, and the management cost is also reduced

THE ADVANEX ADVANTAGE

The Problem

A switch manufacturer contacted Advanex because the local spring maker they were working with was unable to produce springs that met their design specifications. Advanex offered support, despite the fact that the springs they were using were made by a competitor. The customer had produced specifications for the springs on their own and had them produced by a local spring maker but they were found to be over-stressed and ineffective. They tried to use the Advanex design software on our website but needed the know-how of a specialist, so they contacted the Advanex Customer Support Center.

The Solution

Advanex was able to offer superior service and knowledge to meet a specific challenge. This was achieved by:

  • Rapid prototyping and testing
  • Quick and helpful correspondence
  • Knowledge and technical ability

The customer required a functioning torsion spring for use in a new joystick. The customer requested that Advanex design and develop a spring that would continuously work through the full range of movement required.

To strengthen the customer’s relationship with Advanex, we arranged for their engineers and ours to communicate directly due to the complex nature of the project. After discussing the matter, our engineer at the Koriyama Prototype Center designed a spring that was, in theory, up to the task and sent the drawings to the customer.

Using a numerical control multi-forming machine at the prototype center, they produced a sample with more coils to reduce fluctuations in stress and avoid spring setting and also adjusted the leg angles to meet the customer’s required torque levels and add durability.

In all, five prototypes of the spring were produced. All communication was done via telephone and e-mail exchanges with the customer, who appreciated the quick responses from Advanex. During development of their initial product, the customer then ordered a compression spring, which further demonstrated their faith in Advanex’s capabilities.

Specifications

Product

Torsion spring

Forming Method

NC multi-forming machine

Location

Japan

Customer

Switch manufacturer

Application

Joy stick

Market

Electronics

Leadtime

6 months after initial request

Purpose

Achieving a full range of joystick motion

Solution

Mass-production, fast and effective design

Customers Benefit

They remain competitive

ADVANEX GLOBAL NETWORK SUPPORT

The Problem

An electrical equipment manufacturer made a request to the Advanex group for local procurement and overseas production through its global network. In order to reduce costs, the customer wanted to move his production from Japan to Thailand. As the Advanex Thailand factory is located within 500 meters of the customer’s own factory, they approached the group to see if mass-production was possible in Thailand. The customer also demanded competitive quotes from competitors to ensure they were getting a good price.

The Solution

The transition of production from Japan to the customer’s native Thailand was a smooth process. This was due to:

  • An effective world-wide network
  • Consistency and cooperation between the different areas of the group
  • The knowledge of the Advanex staff

The parts used in digital single-lens reflex cameras are technically demanding, requiring advanced processes to produce. Japan would determine the specifications and pricing but manufacturing would be transferred to Thailand to bring down costs.

In order for this transition to be smooth, it was essential that we had a system for developing prototypes in Japan and transferring the technical details to Thailand.

Advanex also needed to develop and manufacture parts with short lead times and respond quickly to changes in design specifications.

The customer was satisfied with the transitioning of mass production to Thailand. Based on the customer’s requests, the Koriyama Prototype Center and the Niigata production factory worked synergistically to produce samples for the customer’s design department. Improvements were made promptly, giving Advanex an advantage over potential competitors. Once approved, the final designs were submitted and explained to Thailand. Niigata offered continued support to Thailand. Making a trouble-free start to mass-production locally for the customer.

Another advantage the Advanex group had over competitors is that both Niigata and Thailand had the same machinery and technical capabilities, which are employed world-wide, making transfer of production overseas easy.

Specifications

Product

Conical, extension and flat springs

Forming Method

Multi slide forming, power press, coiling

Location

Designed in Japan, produced in Thailand

Customer

General electrical equipment manufacturer

Application

Camera parts

Market

Electronics

Leadtime

1 year in development

Purpose

To drive costs down

Solution

Localization of production

Customers Benefit

Target costs met

SWITCH INSERT MOLDING

The Problem

The customer was an electrical switch manufacturer with a problem during assembly of their product. Solder spatter during the connector assembly process had increased costs to an unacceptable level. The spattered solder rendered defective the expensive electronic chips, (supplied as a connector for an air conditioning unit to the automotive industry), leading to a high rejection rates and a substantial increase in costs.

The Solution

The customer had a significant problem that was costing them dearly. Advanex was able to solve the problem through creative use of their advanced technology. We offered:

  • An innovative approach
  • Advanced processes
  • An inexpensive, easy solution

The customer approached Advanex with the need to develop a connector that would not be damaged from solder spattering during assembly. They needed an easy way of protecting the expensive device from damage.

The creativity of Advanex engineers and with proven technology made it possible to find an ideal solution. To prevent solder spattering during assembly, they found that it would be useful to integrate a cover into the product. The cover should not hinder the soldering process, and removal once the component is installed needed to be simple with no risk of damage to the rest of the device.

To do this, the cover needed to be secure but insubstantial enough to allow easy removal. The main factor was the material thickness of the joint portion.

An ideal thickness could not be calculated but the engineer was able to achieve optimal performance through his best judgement.

To manufacture the product, Advanex used our double insert molding technology. The approach to solving this problem has been and object lesson to Advanex staff that demonstrates the importance of creativity in finding a solution.

Advanex is proud to have developed a product that is still vital to this customer 15 years later.

Specifications

Product

Insert molding

Forming Method

Insert molding

Location

Japan

Customer

Switch manufacturer

Application

Electric board connector

Market

Electronics

Leadtime

3 months in development

Purpose

Develop connector preventing solder spatter

Solution

Creativity, craftsmanship

Customers Benefit

Product yield improved dramatically, product

MOBILE PHONE INSERT MOLDING

The Problem

The customer, a leading producer of mobile phone antennas in Japan, approached Advanex with a sketch of a small piece of folded wire that would act as an internal antenna in a mobile phone. At the time (2001), mobile phone antennas had a ‘pop-up’ design, but if this product could be made to work successfully, the design of mobile phones would be greatly improved, while making them smaller. To create a functional internal antenna the customer believed it should be made from a small folded wire spring housed in the body of the phone.

The Solution

From wire spring to a flat spring insert molding, the change in thinking led to huge success. Advanex was able to offer:

  • Innovative solutions to new problems
  • Unrivalled expertise in metal manufacturing methods
  • Resources to meet a huge production demand

The customer requested that Advanex develop the smallest internal antenna possible, with a high receiving capacity. Advanex developed this antenna utilizing a spiral shaped spring of excellent quality, which was a world first.

In order to get a spiral spring to fit into the phone housing, Advanex first made a prototype resin case. However, the customer could not get a stable signal because the pitch of the spring was affected by the phone’s vibrations. Advanex brainstormed the problem and an insert molding engineer proposed using a press processing method that utilized the spiral shape to get a favorable reception. This lateral thinking was the reason for Advanex’s success.

Based on our sketch the customer cut and bonded copper foil onto a handmade resin prototype and achieved the required reception with the Advanex design. Working with the customer, Advanex then developed trial precision flat springs integrated into an intricate plastic molding. Using this technique and our automated insert molding process, Advanex was able to give the customer a product that gave both good reception characteristics and ease of assembly into the mobile phone.

The change in design from a wire spring to a flat spring insert molding ensured high productivity for both Advanex and the customer. It was a world-first product and gained the customer a reputation for innovation in the industry.

Specifications

Product

Insert molding

Forming Method

Insert molding

Location

Japan

Customer

Antenna manufacturer

Application

Internal mobile phone antenna

Market

Mobile phone technology

Leadtime

6 months in development

Purpose

Improving phone design

Solution

Advanced equipment technology, creativity

Customers Benefit

Total sales of over 4 million, a huge success

MEDICAL WIRE FORM

The Problem

The customer was a medical equipment manufacturer that had received reports of accidents occurring with their new product – the lens cover on their halogen lamp had detached due to the fastener becoming loose under heat, creating a potential hazard. Medical institutions demanded the product be improved and the customer had to work quickly to calm the claims against their product as soon as possible.

  • The expertise of the technicians at the Koriyama Prototype Center
  • Keeping down the cost of the solution
  • Meeting production requirements

The customer’s product was used regularly in medical institutions, so it was impossible to collect and repair them all efficiently. They would have to visit all nationwide delivery destinations as soon as possible and replace the defective part to prevent accidents from the lens cover falling off.

It was essential that a simple solution be found so that the customer’s representative could make the repairs easily by themselves without having to modify the units—by making a hole for example.

In addition, because of the number of units it was essential to minimize the cost of this solution.

Due to the urgency of the situation, an Advanex representative took the customer to Koriyama Prototype Center. The most experienced of our technical staff made a trial spring by hand right away, and made a drawing based on the trial spring under the assumption that it would be mass-produced on our multi-forming machine.

After only two trials, the customer was satisfied and Advanex was able to supply the ideal product in just three weeks.

Specifications

Product

Wire forming

Forming Method

Multi-forming

Location

Japan

Customer

Medical equipment manufacturer

Application

Lens cover holder

Market

Medical

Leadtime

Three weeks

Purpose

To secure a lens cover

Solution

Quick response, rapid prototyping

Customers Benefit

Reputation of widely used product was protected

CAR INTERIOR TORSION SPRINGS

The Problem

With only one month until a model change, the customer could not find an acceptable solution to their problem – which was that his engineer was having great difficulty designing a spring with sufficient load for a glove box lid and pressure was building as the deadline approached. An Advanex representative brought the engineer and the product to the Koriyama Prototype Center to help solve the problem.

The Solution

For this difficult problem, Advanex was able to meet the customer’s deadline through:

  • Rapid prototyping and testing at the Koriyama Prototype Center
  • Excellent support and communication
  • Knowledge and advanced methodology

The customer’s problem was that if the spring load was too high, the glove box lid would not open; too low, and vibrations from the car would cause the lid to open. The engineer tested many spring variations but could not find an optimal solution.

With the deadline quickly approaching, the engineer made a drawing of a spring and sent it to the Koriyama Prototype Center. Based on this drawing, and with the advantages of numerical control machines and specialists, samples were prepared in increments of 1 newton around the engineer’s calculated optimal load.

The customer’s engineer then visited this facility and was presented with the spring samples, whereby he fitted them to the glove box and lid assembly. Choosing the best spring, the engineer returned to the customer’s site and proved that the spring passed the durability tests.

However, during assembly, the engineer discovered a possible risk of injury due to the sharp end of the spring. The engineer redesigned the spring to remove this risk and sent the drawings back to Advanex. The spring was redesigned, further improved and finally, after several trials, the ideal spring was supplied within the customer’s one month deadline.

Specifications

Product

Torsion spring

Forming Method

NC machine

Location

Japan

Customer

Plastic parts manufacturer

Application

Car glove box

Market

Automotive

Leadtime

One month after development request

Purpose

To have a specific required load

Solution

Prototyping and testing, development speed

Customers Benefit

Exceeded expectations with a very fast lead time

CLEAN ROOM COMPRESSION SPRINGS

The Problem

A manufacturer of plant equipment based in Hokuriku needed to incorporate springs into a partition they were making for the air conditioning control unit of a clean room. Initially they purchased standard springs from a wholesale supplier made from music wire. They tried several variations but could not make their product work successfully. This led them to approach Advanex via the web.

The Solution

For a customer with no prior knowledge of springs, Advanex was able to provide an ideal product with a prompt and helpful response. We offered:

  • Custom design and development from initial inquiry to end product
  • Rapid design and development
  • Quick delivery

The customer commissioned Advanex to design and manufacture springs suitable for their product, which would be used in clean rooms.

The original springs used by the customer were made from music wire and were thus susceptible to rusting, making them unsuitable for a clean room environment. They requested that the springs from Advanex be manufactured from stainless steel that would retain the original functionality of the previous materials.

The customer had no experience designing springs so they consulted Advanex by telephone and e-mail explaining that by using stainless steel instead of the music wire they were breaking new ground, so we would need to do a redesign to meet their requirements.

A design specification was provided and trials begun. Three trial sets were carried out to reach a suitable solution for their application and the final product was delivered just 25 days after their initial contact with Advanex.

Specifications

Product

Compression spring

Forming Method

Coiling

Location

Japan

Customer

Plant equipment manufacturer

Application

Used in an air conditioning unit

Market

Plant equipment

Leadtime

25 days after the development request

Purpose

To be suitable for use in a clean room

Solution

Rapid prototyping

Customers Benefit

Mass production, short lead time, quick delivery

FLAT SPRING

The Problem

Automobile manufacturers had an urgent need to reduce the cost of procured parts.

Customers are heavy electric manufacturers based in the Tohoku region. The trigger is cost reduction. Customers were asked to make estimates when they were forced to review parts procurement. The designated product is a two-use leaf spring of similar shape to the right and left used for the radiator motor of an automobile. It was the request after feeling the limit in the cost management ability of the competing spring manufacturer who had requested the manufacture of the similar product until then.

The Solution

  • Prototype processing technology
  • Conceptual and technological capabilities
  • In-house made forming machine

Advanex decided to adopt processing by forming machines against the processing by competitors’ press machines until then. In terms of the two advantages of the forming machine:

① to save material costs by reducing waste of material ingestion;
② to allow compression of mold costs by being able to accommodate type 1 and similarly shaped items on the left and right side through part change;
the presentation presented that the unit cost and the cost of gold can be drastically reduced, and the mutual estimation by the materials and parts was winned.

However, the forming process was the first time for the customer, and he felt anxiety. This paper explains the outline of forming by showing moving pictures and photographs with a technician in charge of sales. The company itself draws a manga picture to explain the mechanism of material cost compression, etc., and wins the reliability of the customer engineer of the theorist skin. After that, the factory smoothly shifted to the prototype stage, and at the timing of the process audit in which fine dimension adjustment was completed and the dies were completed, the quality manager of the customer visited the Kashiwazaki Plant and made final adjustments with the quality engineer of Advanex, leading to mass production. The first customer to look at a forming machine at a factory, surprised at the facilities and management system. Advanex is becoming more trustworthy, and other products are being developed.

Specifications

Product

Flat spring

Forming Method

Multi forming machine

Location

Japan

Customer

Heavy electrical equipment manufacturers

Application

Radiator Motor

Market

Electronics

Leadtime

One year after request for development

Purpose

Cost reduction

Solution

Proposal of processing method according to request

Customers Benefit

Successful cost reduction of over 20% per product and reduction of die cost. We will also strengthen our relationship with Advanex as a partner that can place orders for automobile parts with peace of mind in terms of quality

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