Small Investment Solves Snarled Torsion Spring SituationNovember 28, 2017
There’s more to Capital Spring than just the production of various springs. Design and manufacturing modifications that resolve larger production and quality issues for clients have long been a hallmark of the MW Industries Company. Expertise in the fabrication of high-quality extension springs, torsion springs, compression springs, wire forms, four-slide parts and small metal stampings has evolved since 1945, all with an emphasis on customized service and reliance on advanced technologies.
Capital Spring employs the latest CNC coiling technology and new manufacturing techniques for the production of torsion springs (.008 to .312 in. wire diameter) that are used everywhere. These helical components are widely used in military applications, injection molding assemblies, numerous automotive applications, power distribution applications, medical devices, door handle assemblies and many more applications.
The company applied its problem-solving proficiency in providing a remedy for a key OEM account that uses torsion springs in lap restraint applications for their aerospace and automotive markets. The issue started with the design of the spring: a larger-than-optimal pitch between the spring’s coils resulted in product tangling throughout the manufacturing and supply chain processes. In an attempt to minimize the tangling, parts were boxed in smaller lots during Capital Spring’s manufacturing process, during the zinc plating process, during the transportation process, and lastly at the OEM as parts were transferred from department to department. The smaller lots helped but not nearly enough. With an EAU of 1.75 million pieces, there was a lot of tangling!
The remedial approach initially taken by the OEM proved cost-and labor-intensive. An added detangling step was deemed necessary to prevent deformation in the center of the spring cluster. In order to separate the tangled springs, the OEM used a team of 11 workers. All of the extra handling increased their internal production and materials costs to the tune of $11,600 a year!
An opportunity for Capital Spring to tackle the tangling problem arose when new personnel at the OEM thoroughly investigated the suggested change: If a small tooling modification (at a cost of $500) to the stamped metal components to which the springs are attached could be implemented, then Capital Spring’s solution to fabricate closed-wound torsion springs without pitch (the reason for the tangling) would work. The process revision eliminated extra steps for both companies. The cost of $500 delivered more than $11,600 in annual cost savings! Plus, the value-added solution allowed the OEM to benefit even more from the reassignment of the 11 workers, speed-to-market-gains and markedly reduced operating expenses.
To learn how Capital Spring can detangle product design issues and engineer value for your company with customized service, visit their website or call 614-418-0250.