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Optimum Process Selection Story:

Part description: RF Shield

How part is used in finished product: Shields RF waves from leaking out of the electronic product.

Manufacturing process used:

          Stage 1. Laser / Brake

          Stage 2. Laser / punch press form tooling

          Stage 3. Punch press blank, pierce, and form tooling

Secondary operations: Silk screen

 Critical tolerances:

          1. Hole diameters and relationships.

          2. Surface aesthetics of the part.

          3. Position and relationship of fingers.

          4. Quality of screening

Value storyline:
This customer needed a quote the same day, the initial parts on their dock (600 miles away) no later than 5 working days, with an uninterrupted ramp up and flow of parts through the 35,000-piece order. Dayton Rogers quoted the part the same day, using 3 separate manufacturing processes, given the urgency of the project.

          Quote 1. Laser cut and formed on the brake.

          Quote 2. Laser cut and formed with punch press tooling. This method offers a lower price and faster, more cost 
          effective tooling.

          Quote 3. Blank / pierce / form using punch press tooling. This method offers an even lower price and a more
          aggressive production rate.

The customer issued a purchase order the same day using the 3rd quote, a 3-stage modular tooling process. Then Dayton Rogers got to work by downloading the customer's engineering software directly to their laser. The 1st 100 pieces were on the customer's dock on the 4th working day. Dayton Rogers supplied parts for 10 days using their laser while tooling was being built. When the tooling was built the price went down and the number of parts increased. After the flat pattern for the laser / form tooling was proven, the same engineering file was then downloaded to Dayton Rogers' EDM for the cutting of a blank and pierce die. This process reduced the piece price even further and the production ramped on schedule.

Value Summary:

• Dayton Rogers was able to provide manufacturing flexibility and process selection for this customer.

• Instant / accurate communication between engineering files, quotes, and manufacturing processes.

• No paperwork meant a faster transition and no chance for human error.

• Piece price was lowered twice; the second was half the original price.

• Processes were driven from the customer's files resulting in consistent production.

• No rejects and no disruption to manufacturing.

• The silk-screened artwork was also e-mailed as a PRO-E DXF file, which eliminated errors and decreased the time to make the screen from 3 days to just 2 hours.

Dayton Rogers provides Design Assistance for our customers, including Design Handbooks and even a Technical Design Seminar. Follow this link on our website to learn more. Free Technical Design Seminars