Fastener Technology International Magazine
December 2023/January 2024
Written by: Brett Kuhn
Customer Support Manager
National Machinery LLC
Listening to feedback from customers led to the development of a variety of upgrades and enhancements to FORMAX® machines.
Since its inception in 1989, FORMAX® has not only stood
the test of time but along the way has actively undergone
continuous improvement. Formax machines built today are
vastly improved from those first machines. Utilizing customer
feedback, National Machinery engineers have made
countless upgrades and enhancements. Virtually all major
components have been improved—from feed, to transfer, to
heading slide. The number one rule along the way has been
this: every design change must be retrofittable. That means
that whatever the vintage of your FORMAX, there is an opportunity
waiting to bring it to today’s standard.
Let’s explore the advantages of rebuilding your FORMAX
to incorporate these technological advancements so that you
get the most out of your machine.
Technological Improvements
The Table seen below presents a list of upgrades that will
allow you to get the most out of your FORMAX.
For this Rebuild and Upgrade Emphasis article, let us
drill in on several specific upgrades, in order to examine the
benefits of upgrading to today’s standard.
Updated Electrics/Controls: FORMAX machines are
designed to give decades of service as shipped, but we all
know that electrical components become obsolete much
sooner than mechanical components. When we do need to
update obsolete electrical components, the good news is that
we can get increased functionality beyond simply replacing
“in kind.” For FORMAX machines, the most interesting
example is the incorporation of remote connectivity solutions.
By allowing access to your machine’s control system
through an EWON communications system, you can not only
utilize machine data to enhance productivity, but also allow National’s support team to remotely connect to your machine
for troubleshooting, reducing your machine’s downtime. In
recent years, we have all experienced extensive lead-times
for electrical components. Taking a proactive approach by
replacing controls before a failure can be crucial to avoid
unplanned downtime.
Transfer Housing Upgrade: Efficient high-speed machine
operation relies heavily on the transferring system. To capitalize
on their repeatable setup feature, FORMAX machines
require transfers capable of accommodating complex parts,
maintaining tight tolerances and sustaining high production
rates. Our Transfer housing upgrade incorporates features such
as a zero-clearance transfer slide, positive flow slide lubrication,
increased rigidity, locked positioning and hardened surfaces
for clamping and pivot bushings. These enhancements
contribute to improved long-term part indexing accuracy,
reliability and component durability. The transfer system can
also integrate hydraulic clamping for swift, easy and precise
changeovers, ultimately enhancing machine uptime and productivity.
The FORMAX 2000 Transfer is compatible with
all vintage and size FORMAX machines featuring the straight
across transfer configuration.
Case Study Examples
Now let us examine several case studies that are centered
around the above upgrades.
Case 1: Electrical Upgrade—Avoiding the Cost of Unplanned
Downtime: The Pareto chart on the top of the next
page illustrates the top contributors to machine downtime for a
real-life customer’s vintage 2001 FX35M over the past year. In
total, this specific machine had 500 hours of downtime related
to maintenance support, with more than 65% of downtime
being related to electrical components issues.
Key Assumptions include maintenance hourly rate of
US$35.00 and lost revenue hourly rate: US$400.00
With these assumptions, the estimated cost of maintenance
time loss is US$12,250 and the approximate lost revenue is
US$100,000, resulting in a US$112,250 cumulative loss that
could have been prevented with the simplified electrics and
wiring harness upgrades.
Case 2: Electrical Upgrade—Using Virtual Service
Support to Avoid Unplanned Downtime: In another real-life
scenario, one customer recently implemented a controls
upgrade, and soon after realized the added functionality of
remote machine access. During the weekend operation, the
customer faced a “Machine Down” situation. After some
initial troubleshooting, the maintenance personnel contacted
National Machinery’s 24/7 hotline for support. From here, our
Customer Support Representative initiated a Virtual Service
call with one of our experienced Electrical Engineers.
After reviewing the fault codes found within the program
of the machine, the problem was determined to be a damaged
kick-out adjustment sensor. He guided the customer in replacing
the sensor and calibrating the settings. The total cost of
the virtual service call was US$450.
Without the ability to provide remote Virtual Service, the
path to a solution would have been very different. Dispatching
a technician on Monday, with arrival on Tuesday, would result
in a three-day delay and a substantial loss in revenue. The total
cost of the “in-person” service call including travel expenses
and other charges, would be nearly US$6000. Add an extra US$10,000 in lost revenue, and the total cost impact would have been US$15,000. This virtual service call made possible by the simplified electrical upgrade, not only saved calendar time, but also prevented unnecessary costs and lost revenue.
Case 3: Transfer Housing and Heading Slide Upgrades—
Increasing Quality and Reliability: The Pareto chart provided below presents another example from a customer, revealing the primary factors contributing to the downtime of their vintage 1997 FX55L machine. Most notable were the challenges associated with holding part length and quality, which accounted for 300 hours of downtime last year. The specific part this customer was trying to produce had exotic features and extremely tight tolerances. This requires a machine to uphold high precision and repeatability.
At the time, the machine operated at 120 strokes per minute
(SPM). Any increase carried risk of parts dropping, and overall
decline in the required quality standards for parts produced.
Complicating matters was the machine’s age, featuring the
original carbide puck liner and pre-Formax 2000 transfer.
More than 70% of the recorded downtime for this machine
was associated with challenges in part control and precision.
After consulting our Technical Support group, the customer
opted to invest in both the FORMAX 2000 Transfer Housing
and Heading Slide Liner upgrades. Following the successful
installation of these upgrades, the machine’s operational
speed surged to over 200 SPM, resulting in a 67% increase in
production. The increase in productivity directly translates to
a considerable increase in revenue for the customer.
Summary
The design improvements made to FORMAX over the
years can be added to your FORMAX machine, no matter
the vintage. The modular standardized design of FORMAX
allows it to be easily upgraded, whether as part of a machine
rebuild or as a targeted project in your plant. Upgrading your
National FORMAX machine can significantly enhance efficiency, performance and maximize the value of your investment.
Company Profile: National Machinery is a global leader in advanced
cold forming machinery, process technology and customer support products
and services. Through continuing R&D, advanced manufacturing
capability and global sales and service network, National has established
its position as the “World Leader in Metal Forming Technology”.
We strive to be focused on long-term growth through market and technical
leadership. www.nationalmachinery.com