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McGregor Metal's Story: Life Before & After a Servo Press
Many engineers and plant managers are aware of the benefits a servo press can bring to a manufacturing plant, yet they often wonder just how significant these benefits are. Is the difference between a servo press and a mechanical press like comparing apples to oranges, or is it more like apples to steak?
Seeing is believing when it comes to understanding the substantial improvements a servo press offers. McGregor Metal, an Ohio-based metal stamper, acquired a 440-ton servo press in 2021 and has not looked back. In nearly every possible area, McGregor Metal has seen improved processes to validate their expectations of servo technology.
Good Ole Fashioned, Hard-Nose Stamping
McGregor Metal, a contract stamper with over 40 years of industry experience, began as a small stamping operation and grew into a nationwide supplier for the automotive, appliance, and electronics industries, among others. Larry Borders, McGregor Metal's Tooling Engineer, shared insights into their operations before the servo press acquisition. At the time, McGregor Metal had 13 presses in the factory running anywhere from 30 to 50 strokes. The company was doing well but lacked a competitive advantage that could increase production and overcome some operational inefficiencies, including slow setup times and high defect rates for more challenging parts.
When McGregor Metal was prized with a package of 100 part numbers, leadership decided the company must look at different methods of manufacturing to fulfill the new package they had recently acquired. After extensive research, McGregor Metal decided to purchase the SEYI SDG2-440, a 440-ton direct-drive servo press. They believed that the new technology could be the competitive advantage they needed for their future.
Servo Serving McGregor Well
McGregor Metal gained a significant competitive edge by incorporating SEYI servo presses into their operations. The company has experienced remarkable improvements, such as increased output, reduced downtime, easier operations, improved die life, and enhanced quality.
Larry Borders, McGregor Metal's Tooling Engineer, highlighted the profound impact of the servo press: "When customers come in and see the press running beside the servo, they see it’s running half the speed. And then they see the quality of the parts of the servo and die is in there half the time, there’s no comparison," he explained.
Higher Output
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One of the most significant advantages of using servo presses is the ability to dramatically increase output. Larry Borders stated, "Anything we are able to put back there, we are able to double. Any die, any part, we can double." This boost in productivity is achieved even when the press operates in half motion rather than crank motion. With half motion, output can at least double, showcasing the servo press's efficiency and flexibility. |
To put it in perspective, the SEYI servo press now runs one-third of all McGregor parts - a facility that runs 12 other stamping presses.
Improved Quality
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The team at McGregor found that parts, which previously faced issues in mechanical presses, performed exceptionally well in the SEYI servo press. "We've seen examples of parts that just didn't react right in our other presses,” stated Borders. "We put it back in the servo, and the dang thing makes an excellent part. So far, 10/10 parts put in the servo come out with better quality." |
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This shift has led to the consistent production of quality parts, minimizing the time and resources spent on troubleshooting.
Lower Defection Rate
Quality control is critical in metal stamping as one flawed part can lead to expensive buybacks in the future. Borders shared one example involving a part with a small draw that posed challenges in mechanical presses. This part had a 50% defect rate, which wasted sheet metal and cut output by 50%. After moving the die to the servo press, Borders could slow the decrease the speed during the working portion of the stroke for improved forming. Doing so produced a much better part with a defect rate close to zero.
Quicker Die Change
Efficiency in die change is another area the servo press has enhanced operations at McGregor Metal. Borders stated, "Our die changes in the servo have been cut in half." After programming a job, McGregor no longer must change the shut height, adjust sensors, and modify the counterbalance system as these settings are automatically done by the press to streamline the process.
As each SEYI servo press features 200 sets of job storage in memory, the die change process can be done right away, reducing downtime significantly. This rapid changeover capability enhances overall productivity and flexibility in operations.
Easier Tooling
Die setup and troubleshooting often consume valuable production time for manufacturers. Borders explains how the servo press's handy pulser wheel has revolutionized these processes, quickly becoming his favorite tool on the press. The pulser wheel enables precise adjustments, eliminating guesswork when setting the pilot release for optimal performance. Borders can inch the slide forward to find the exact degree where the pilot enters, allowing him to set the pilot release with pinpoint accuracy. He then repeats this process to close the pilot release accurately. "What’s so helpful is getting the pilots set just right, allowing the steel to flow until the last possible second," Borders notes. "Every time it progresses, it's spot on.”
Furthermore, the pulser wheel dramatically reduces the time needed to address minor issues that trigger sensor alerts. Borders highlights that this tool allows McGregor to resolve problems in a fraction of the time compared to other presses, enhancing overall efficiency and minimizing downtime.
Easier Operations
McGregor enjoys easier operations with the servo press. The simplicity of the machine means operators can focus more on monitoring parts and ensuring quality rather than constantly adjusting the machinery. "Operations are much easier... you don't have to worry about much once it's set up," stated Borders.
If a sensor does go off, the ability to reverse the slide using the pulsar wheel also helps prevent damage during sensor malfunctions, keeping operations simple and safeguarding the equipment.
Improved Die Life
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One of the most impressive benefits observed at
McGregor Metal is extended die life. Dies used in the SEYI servo
press now last three times longer than those in mechanical
presses. "We can now run 300,000 pieces before sharpening compared to
100,000 pieces on a mechanical press," reported Larry Borders. |
This improvement not only reduces maintenance costs but also increases efficiency in their manufacturing process.
Looking Ahead
After seeing the benefits that McGregor Metal's SDG2-440 has brought the factory, the company is now an advocate for servo technology. Larry Borders now believes two more servo presses could eliminate six or seven mechanical presses in their factory.
"If and when we invest in another servo press in the future, it will be a SEYI," explained Borders.
While it is wonderful seeing SEYI equipment used to its fullest potential, therefore bringing a host of benefits to a company, the best part is building a relationship with the incredible people at a company like McGregor Metals. We thank each and every employee at McGregor Metals for their stories that make our entire industry a better place to work!
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