⚠️ Disclaimer: Due to customer confidentiality agreements, these part models are representations only. I have created simplified models to visually demonstrate the process improvement project without disclosing proprietary designs.
The Challenge
I was tasked with assembling pins into parts at Pivot Manufacturing. As I began the process, I quickly identified three critical issues with the existing approach:
Problem #1: Improper Equipment & Surface Damage
The original process used a Bridgeport mill as a press, which was fundamentally not designed for this application. This approach had multiple drawbacks:
- The mill's design made clamping difficult and unreliable
- The process was physically tiring and inefficient for repetitive assembly
- The steel plate scratched the chemical film coating off the parts, causing quality issues
Problem #2: Pin Positioning Challenges
Manually positioning pins during installation was problematic:
- Pins were difficult to hold in place during the pressing process
- No systematic positioning system led to misaligned installations
- Inconsistent results and rework was common
Problem #3: Die Pin Release Issues
The die pin frequently stuck to the part after installation:
- Die pin did not release properly as designed
- Required manual intervention to separate part from tool
- Added time and risk to each installation cycle
The Solution
Better Equipment: Repaired Arbor Press
I met with the shop engineers and experienced machinists to find a better solution. Together, we identified an old arbor press that had been stored in the back of the shop. We worked together to restore it to working condition.
To adapt the arbor press for our application, I designed and machined custom bushings in-house to fit the 1/4" pin into the 1/2" hole of the press. This simple but critical adaptation solved multiple problems:
- The arbor press was specifically designed for pressing operations, providing reliable clamping force
- It successfully pressed and molded the pins around the parts (solving Problem #1)
- The press released cleanly after each cycle (solving Problem #3)
Die Pin Refinement
To further improve die pin release, I took the die pins to the manual lathe for in-house tooling:
- Ground approximately 0.003" off the die pin surface
- This subtle modification significantly improved release characteristics
- Applied cutting oil to further lubricate the surface during operation
Custom Fixture Design
To address pin positioning (Problem #2), I designed a 2D-printable fixture that:
- Precisely located all pins in their correct positions
- Allowed parts to be placed on top of all pins simultaneously
- Enabled the entire assembly to move around the press together
- Eliminated manual positioning errors and inconsistencies
Results
Significant Time Reduction Achieved
80% reduction in assembly time per part
Key Improvements
- Drastically reduced assembly time from 12-13 minutes to 2-3 minutes per part
- Eliminated surface damage to parts through proper equipment selection
- Improved consistency and reduced rework through systematic pin positioning
- Significantly reduced operator fatigue through ergonomic equipment and process design
- Increased production capacity dramatically without additional labor
Key Takeaways
This project demonstrated the importance of:
- Problem Analysis: Taking time to understand why a process wasn't working
- Collaboration: Working with experienced machinists and engineers to find solutions
- Equipment Knowledge: Recognizing that the right tool for the job makes all the difference
- Iterative Improvement: Making small refinements (like the 0.003" die pin adjustment) that compound into significant gains
- Practical Engineering: Simple, elegant solutions (custom bushings, printable fixture) often work better than complex ones