PowderED METAL CONVERSION

Problem

Our customer was looking to drive down the cost of a component that was currently being machined. This application also involved assembling a set screw into the machined component on the manufacturing line which was creating a bottle neck during production.

The NSK Solution

NSK's recommendation was to change the current manufacturing process of machining the component to have it produced by powder metal. Not all parts can effectively convert from machining to powder metal, however, this component was a perfect fit for the conversion. NSK also offered to assemble the 2 components for the customer prior to parts going into the production line.

RESULTS

1. The customers annual usage was 15,000 pieces and by changing the manufacturing process to powder metal NSK was able to save the customer over $20,000 a year.
2. In addition, NSK saved the customer about 30 labor hours by NSK handling the assembly of the components.

---

Dissimilar Metal Application Analysis

Problem

Our customer had an application that involved mating a steel pin with a Magni coating and a stainless steel push nut. When NSK reviewed this assembly our first concern was these dissimilar metals were actually accelerating the galvanic corrosion process. This brought the opportunity to address the concern of corrosion and potentially a cost savings idea since the annual usage was around 2,000,000 pieces.

The NSK Solution

NSK's first recommendation was to change the push nut to spring steel with the same Magni finish. This solution would address the concern with dissimilar metals that were accelerating the galvanic corrosion process. This new application also increased the force to remove the push nut off the pin because of the spring steel. All together the push nut was a better fit for the application but the best part was it saved the customer around $300,000 a year.

RESULTS

1. Saved the customer around $300,000 a year
2. Reduced corrosion in the application
3. Increased the disassembly force of the mating parts