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All the case studies you'll see listed on this page are workholding examples provided to us by our customers. Click on any of the thumbnails below for the complete case study.

Case #1
Axle Clamps
SCPS
Fixtures
Case #3
Circuit Board Spacer
Case #2
Chassis Front Panel
Case #5
Adjuster Bracket
Case #4
Trigger Latch Op1


One advantage of the system is the ability to quickly change setups in about 20 seconds. Mounting various workholding devices eliminates long setup times between jobs.

Many of our customers mount vises and engrave the work offsets into the top surface. This way an operator simply enters the offsets with no need to touch off a part or indicate the vise.



Case Study #1
Part: Axle Clamps Size: X 1.000, Y 0.675, Z0.750
Click Image for Details
Quantity: 200 units Setups: 1 per pallet, 3 ops
Time Savings: 5 hrs 33 mins Dollar Savings: $416*

This job was originally run in 3 operations using two vises in a vertical machining center. The total setup time for each operation averaged 30 mins. The parts were machined 4 at a time and changed out by an operator at the end of the cycle.

The following reorder, the company used the Workholding System. All 3 operations were combined onto a single pallet so each cycle yielded 6 finished parts instead of 4 parts still requiring 2 more machining operations. Setup time was cut from 90 mins to 20 mins and the time the machine sat without running (spindle idle time) decreased from 35 seconds to 15 seconds per cycle. This translated to the individual part change time dropping from 26.25 sec per part (25sec ÷ 4 parts x 3 ops = 18.75sec) to only 2.5 seconds! (15sec ÷ 6 parts x 1 op = 2.5sec)

The Bottom Line: Parts per cycle went from 4 unfinished parts (requiring 2 more operations) to 6 completely finished parts. Spindle idle time was cut by a whopping 90% and overall production was boosted by 53%. This job proved that significant savings can even be made on smaller quantity orders.

Machining Times Using Standard Vises
 
Cycle Time
Part Change Time
# of Changes
Total Time
Operation 1
4:48
0:35
50
4h 29m
Operation 2
3:30
0:35
50
3h 24m
Operation 3
0:39
0:35
50
1h 2m
      Total Run Time
8h 55m
      Setup Time
90 minutes
      Total Job Time
10hrs 25mins

Machining Times Using the SCPS
 
Cycle Time
Fixture Swap Time
# of Changes
Total Time
Operation 1
7:45
0:15
34
4h 32m
      Total Run Time
4h 32m
      Setup Time
20 minutes
      Total Job Time
4hrs 52mins


Case Study #2
Part: Connector Mount Size: X 4.400, Y1.000, Z0.125
Click Image for Details
Quantity: 320 units Setups: 2
Time Savings: 7 hrs 53 mins Dollar Savings: $591*

Projecting the job wouldn't be finished before the tight due date, the foreman quickly designed and cut a fixture. Parts were held 4 per pallet using Pitbull clamps. Setup time increased to an average of 60 mins per operation due to the extra time needed to create the fixtures, however what used to take 20 seconds to swap out a single part was now taking 15 seconds to change the entire fixture of 4 parts; a new average of 3.75 seconds per part. This average part-change time was cut down by 81%.

The Bottom Line: Spindle idle time was reduced by 81%. Overall production was boosted 27%. This job has repeated 5 more times to date saving the company $3,546!

Machining Times Using a Standard Vise
 
Cycle Time
Part Change Time
# of Changes
Total Time
Operation 1
3:46
0:20
320
21h 52m
Operation 2
1:00
0:20
320
7h 07m
      Total Run Time
28h 59m
      Setup Time
30 minutes
      Total Job Time
29hrs 29min

Machining Times Using the SCPS
 
Cycle Time
Fixture Swap Time
# of Changes
Total Time
Operation 1
10:32
0:15
80
14h 23m
Operation 2
3:40
0:15
80
5h 13m
      Total Run Time
19h 36m
      Setup Time
2 hours
      Total Job Time
21hrs 36mins


Case Study #3
Part: Circuit Spacers Size: X 6.25, Y6.25, Z0.125
Click Image for Details
Quantity: 1000 units Setups: 1
Time Savings: 23 hrs 47 mins Dollar Savings $1784*

Our customer was originally using a fixture plate and then holding one part at a time in a standard vise. The part's thickness and flatness was critical. They were having problems holding tolerances due to small chips left on the fixture plate. Also, they were using 6 screws to hold the parts which made part changes extremely slow.

We introduced them to our Manual Pallet Changer and designed a custom fixture plate to piggyback on one of our pallets. They were now cutting 2 parts per cycle and, to their foreman's delight, had NO SCRAPPED PARTS because the operator had time to thoroughly clean the fixtures. What originally took about 5 days to complete, they were shipping in 3. They realized a 47% increase in output on the first job.

The Bottom Line: Part per cycle doubled. Spindle idle time decreased by 91%. Overall production was boosted by 47%. Best of all, this job has repeated 5 more times to date saving the company $10,704.

Machining Times Using a Fixture Plate
 
Cycle Time
Part Change Time
# of Changes
Total Time
Operation 1
1:40
1:20
1000
50:00:00
      Total Run Time
50:00:00
      Setup Time
30:00
      Total Job Time
50hrs 30mins

Machining Times Using the SCPS
 
Cycle Time
Fixture Swap Time
# of Changes
Total Time
Operation 1
2:55
0:15
500
26:23:20
      Total Run Time
26:23:20
      Setup Time
20:00
      Total Job Time
26hrs 43mins


Case Study #4
Part: Trigger Latch Op1 Size: X 1.30, Y1.00, Z1.00
Click Image for Details
Quantity: 880 units Setups: 1
Time Savings: 11hrs 22 mins Dollar Savings: $853*

In a previous production run, our customer set up four 6" vises across the table of their Haas Toolroom mill. They were completing 8 parts every 30 minutes.

Upon installing our Workholding System they were able to hold 18 parts on a single 6x12" PreEngineered EZ Pallets. They were now cutting 18 parts every 54 minutes.

The Bottom Line: Spindle idle time decreased by 94%. Parts per cycle more than doubled from 8 to 18. They saved $853 on one operation alone, not to mention they would have needed 9 vises to hold this many parts. The math: 9 Vises x $450 per vise = $4,050!

Machining Times Using Standard Vises
 
Cycle Time
Part Change Time
# of Changes
Total Time
Operation 1
26:00
2:00
110
51:20:00
      Total Run Time
51:20:00
      Setup Time
60 minutes
      Total Job Time
52hrs 20mins

Machining Times Using the SCPS
 
Cycle Time
Fixture Swap Time
# of Changes
Total Time
Operation 1
49:30
0:15
49
40:37:45
      Total Run Time
40:37:45
      Setup Time
20 minutes
      Total Job Time
40hrs 58mins


Case Study #5
Part: Adjuster Bracket Op1 Size: X 1.355, Y0.985, Z1.268
Click Image for Details
Quantity: 5000 units Setups: 1
Time Savings: 27 hrs 53 mins Dollar Saving: $2091*

Previous to purchasing a vertical machining center our customer, Chariot Carriers Inc, was using small vises to hold parts individually as an operator drilled holes with a drill press. They were completing 2 parts per minute.

Now using the system as a Manual Pallet Changer in their new VMC, they were able to hold 24 parts on a custom designed 6x16" paIIet using Uniforce Clamps. They were now drilling 24 parts every 2 minutes 30 seconds.

The Bottom Line: Spindle idle time was only 15 seconds to change out a pallet of 24 parts. They improved production by a whopping 200% and saved $2091 on the first job alone!

Machining Times Using Standard Vises
 
Cycle Time
Part Change Time
# of Changes
Total Time
Operation 1
0:20
0:10
5000
41:40:00
      Total Run Time
41:40:00
      Setup Time
10 minutes
      Total Job Time
41hrs 50mins

Machining Times Using the PRS
 
Cycle Time
Fixture Swap Time
# of Changes
Total Time
Operation 1
3:45
0:15
208
13:52:00
      Total Run Time
13:52:00
      Setup Time
5 minutes
      Total Job Time
13hrs 57mins

* "Dollar Savings" are calculated by multiplying a $75/hr machine rate by "Time Savings".

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