Flame Detector Sensor
Overview
Focus:
Waste ReductionIndustry:
IndustrialDimensions (mm):
98 x 30.5Weight (g):
9406-8 Weeks
Design Support
Adjustments
3-Year
Complex Process
Reduced Scrap
This flame detector sensor is predominantly used in oil and gas refineries. Texmo Blank manufactures it in our facility in Coimbatore, India for ESP Safety Pvt. Ltd. This part is made using CF3M alloy; a low-carbon variation of austenitic stainless steel. We have been working together for almost three years now. We were able to deliver this part within 6-8 weeks from the concept stage.
Concept Development
The Texmo Blank engineering team was fully involved with the concept development for this component, and made changes in line with design and manufacturing tolerances. We also advised on the design of the part in relation to Texmo Blank’s die-manufacturing feasibility.
Prototyping
For initial trials a prototype injection tool was machined from aluminium for a low volume sample run. This was the most cost-efficient way to provide the customer with a sample run to check and use to either make changes or approve the design for full production.
During the first sample run we faced more rework and scrap due to positive metal at the inner profiles. Our product and process teams reviewed and analysed the root cause and made adjustments, which reduced the amount of scrap significantly.
Manufacturing Processes
For this part we use our ceramic mold investment casting process, with a robotic system. For machining we used our turning and grinding machines.
There is a high risk of shrinkage for this part, as at certain points it has a wall thickness of more than 20mm. Our gating, assembly method, consistency of manufacturing process and 100% visual inspection ensures the product quality and reliability. We also hold specialised qualifications that guarantee process stability and we work hard to stay up to date with concepts such as lean management to further ensure this.
Quality Control
We maintain critical dimensions using machining after heat treatment. Specifically, we needed to maintain an inner hole with a concentricity of 0.05mm and a run out of 0.1mm.
Our production part approval process is required for every customer and is also a key part of our quality control process. 100% visual inspection is also guaranteed for every part before we ship them to customers, and we have a defect catalogue available to all shop-floor staff to assist them in categorising good and bad parts.
Impact
Thanks to our optimised gating and assembly methods, we were able to achieve better yields on castings than our competitors.
We have plans to further develop this part and modify our assembly method to reduce material waste and increase the yield.
Get In Touch
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If that sounds like an investment castings partner you’d like to work with, you can book an introduction call with our friendly and knowledgeable New Relations Team — in a language and time zone to suit you.