Modern manufacturers are under increasing pressure to minimize production costs without sacrificing product quality or equipment reliability. No one understands this predicament better than high precision die casting manufacturers. Trying to minimize cost associated with scrap and the expensive tooling bodies required for high precision die casting while delivering a consistent product to customers requires balance.
Pace Industries, one of North America’s leading full-service aluminum, zinc, and magnesium die casting manufacturers, found that balance with Rosler. The company needed a cost-effective solution for finishing automotive castings in one of their Mexico facilities. A used through feed tumble belt shot blast machine from Rosler Metal Finishing, USA which had been used in one of Pace’s other facilities was available, but in need of some attention.
The Rebuild Process
Originally built in 2005, the Rosler RMBD shot blast machine had 2,357 hours on it. As expected with a used machine, a rebuild would be required to get the machine back up to operating condition. Equipped with a wet dust collector and two Rosler Hurricane turbines, the turbines were still in excellent condition despite the machine’s age. Pace reached out to Rosler Metal Finishing, USA to inspect and rebuild the machine.
To start the rebuild process, the machine was shipped to Rosler’s facility in Battle Creek, MI, where their service team thoroughly inspected the machine to determine which parts required replacing in order to get the machine back up to operating condition.
Upon inspection, it became clear that before the machine could be operated several key components would need to be replaced including damaged ducting, worn polyurethane slats and belts beneath the blast turbines, a new motor for the sludge conveyor, and miscellaneous components for the wet collector.
In addition to replacing components for the wet dust collector, a significant amount of dried sludge needed to be removed.
Once the machine was up to operating condition, it was cleaned and freshly painted before its delivery to Pace.
Communication is of the utmost importance during a rebuild project like this. As such, Rosler’s service team was in continuous contact with Pace during the rebuild, providing updates on parts that needed to be replaced and progress reports. Rosler also agreed to remotely provide training for Pace once the machine was delivered.
This relationship was put to the test during the project as several items were lost or damaged by the shipping company during the machine’s journey from Rosler’s facility in Michigan to Pace’s facility in Mexico.
A control panel, replacement gear motor, and other items were lost, putting the September delivery date in jeopardy. Initially Rosler reached out to its parent company in Germany to provide a replacement control panel, but the lead time was not suitable for Pace’s needs. To solve this problem Rosler worked with Pace to acquire a control panel from a third party and Rosler agreed to send technicians to Pace’s facility to wire the control panel on site, in addition to sending technicians to troubleshoot the setup of the machine and provide training.
According to Natividad Polanco, maintenance manager at Pace Industries, the greatest benefit of working with Rosler was, “maintaining the originality of the machine concept with its spare parts and systems, in addition to all the engineering support.”