World Class Manufacturing,

Manufacturing News, Source : The Manufacturer US
Published : 03 Jan 2007 19:43

Guest editorial by Harald Kofler, American High Performance Seals
A mid-sized maker of automatic lubrication systems couldn't get an off-the-shelf seal to last long enough in the prototype of its next generation of systems. The stiffness of the material made the seal buckle instead of yielding. None of the off-the-shelf seals had the operational life needed for the new model, which would eventually become a component in a wide range of machinery, including power presses, packaging machines, mechanical and materials handling equipment, textile machinery, food processing equipment.

Like most mid-sized businesses, the company assumed that custom designing a part would raise the cost of the product by too much. Historically, only large companies that needed very large quantities of a seal could afford to customize seal design. Other companies settled for off-the-shelf sizes in standard materials.

But the emergence of faster and more comprehensive software, new energy- and materials-efficient manufacturing technology and advanced materials has combined to lower the cost of designing and manufacturing small lots of virtually any part in almost any material. For the same cost as off-the-shelf seals, the lubrication system maker was able to order a custom designed piston seal that limited rocking motion, reduced fluid seepage and lasted beyond the life of the system.

Much has been written about how manufacturing and information systems have created a plethora of product choices for consumers in an astonishing number of areas, such as food and beverages, clothing, house goods, paint, financial products and entertainment. Many are now calling mass customization "the long tail" of retailing. Whatever we call it, we are living in "have it your way" world in which consumers can order up exactly what they want.

More quietly, industrial products have also begun to enter a "have it your way" world. The experience of the lubrication system manufacturer reflects a paradigm shift occurring among original equipment manufacturers all over the world. The number of applications in which it is most cost-effective to use a custom-designed part has increased exponentially in recent years.

The result is that companies in all industries, and in particular smaller enterprises, are increasingly using custom-designed parts, and thereby gaining a competitive edge from the components inside their products or the manufacturing equipment or systems they use to make their products.

Custom-designed parts can improve the performance of a product or piece of equipment in several ways, including:

* Achieve the ideal shape, thereby reducing or eliminating leakage.

* Lower friction, which can reduce power needs.

* Increase durability, leading to less downtime.

* Simplify, and thereby lower, the cost of the design.

Think of the impact of improving the durability of a small seal or gasket in a piece of manufacturing equipment that requires several workers when in operation. Increasing the lifetime of the seal reduces the time the machinery and the workers assigned to it are idling because the maintenance department is replacing it. A custom design that is more durable than the off-the-shelf version can therefore cut costs substantially.

"Have it your way" manufacturers tend to be smaller companies specializing in one type of part or in serving a limited number of industries. But the criteria for evaluating custom parts designers parallel what's important in evaluating any vendor: delivery times, product quality, flexibility in meeting your company's needs. In the world of parts, that translates into three factors:

1. Can the custom manufacturer meet your deadline? When time is of the essence, such as when a piece of equipment remains out of service waiting for the part, companies know they can depend upon a supplier to have most standard part types and sizes available. But the edge in fast turnaround that off-the-shelf products enjoy is rapidly being eroded. Some custom parts makers, large and small, now offer one-to-four day turnaround for their custom-design parts. When contacting a custom parts maker, it is wise to ask up front what the delivery time will be.

2. Will the custom parts manufacturer accommodate your quantity? Many OEMs working on prototypes or small companies order relatively small quantities. While many custom parts manufacturers are able to design for small volumes, some will require a minimum volume or purchase price to awake their design team. It's also possible that the smaller order will not receive white-glove service. It's wise not only to tell the potential vendor what your likely quantity is upfront, but also to ask for references of customers who purchased similar quantities.

3. Does the company have the engineering capabilities? It's appropriate to inquire about the parts design experience not only of the company, but also of its engineering team.

"Have it your way" manufacturing is here to stay. I anticipate that in the not too distant future most companies will stipulate custom-designed parts for most of their new and retrofitted equipment, assemblies and components. The combination of better design and more durable material enables the custom part to do its job better than an off-the-shelf approximation. The longer-lasting, better fitting custom part is similar in cost today to the standard part, and has the potential to lower energy, maintenance and replacement costs in the future.

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Harald Kofler is president of American High Performance Seals, Inc., a western Pennsylvania-based custom seals manufacturer. hkofler@ahpseals.com

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