Setting the Future in Motion

Throughout our history, we have held the position of automation innovators for the powdered metal industry. From the early days of Keystone—and continuing today—whenever a necessary technology was unavailable, we set out to create it.

In developing new industrial automation capabilities, our motivation is to stay true to our purpose: doing what is right to serve the customer. In some cases, automation projects come from direct customer requests. The goal is always continuous improvement: to provide a more capable, efficient, or cost-effective operation.

Some of our achievements include:

• Machining stations

• Multiple-coil induction heat treating units 

• Presses, from 3 ton to 1,650 ton CNC

• Secondary equipment

• Sintering furnaces

Although we emphasize customer satisfaction, we remain aware of the potential effects of industrial automation on our employees. We view automation equipment as a way to raise the ability level of our company and the communities we belong to.

Buy vs. Build: Reducing Customer Cost through Value-Added Engineering

Challenge

The one-way clutch (OWC) transmission assemblies we manufacture for an automotive customer use an automated, multi-station machine for assembly and test. Several hundred mechanical and electrical elements must work in conjunction in this machine to produce 100%-tested one-way clutches consisting of up to 24 separate components. Six machines were necessary to meet production targets, representing a significant upfront capital investment for the customer.

The Keystone automation engineering group realized we could reduce the expense by designing and building a machine internally. To convince the customer of our capabilities, our version had to perform as well as or better than the recommended supplier's equipment, at a lower cost.

Keystone Solution

Calling on our wealth of experience in constructing in-house equipment, the automation engineering team designed and built the machine from scratch.

To keep costs down and still meet the required functionality, we emphasized simplicity. For instance, our chosen laser welding solution performed to specifications and yet was $70,000 less than the system used in the original equipment.

Results

Our automated OWC assembly solution exceeded the performance of the recommended supplier's machine—at a cost savings of more than 35%. With an assembly goal of zero defects, the machine has consistently achieved quality expectations.

From the customer’s perspective, they saved significant capital at the outset, and they continue to benefit from reduced downtimes with our in-house personnel performing all upgrades and maintenance tasks.

When we shared our design with the original equipment builder, they incorporated some of the innovations into their commercial version.

Overall, we achieved long-term mutual benefits through strengthened relationships with both our customer and an equipment supplier.