HVAC Mass Volume Header Plate

HVAC Mass Volume Header Plate

When a long-standing HVAC client modified a large component to improve performance, they came to Ajax for help in the fabrication. A critical link in a long supply chain, the 43-inch precision sheet metal part includes 5 compound bends.Quality problems would shut down the production line. We provide 20,000 high-quality pieces per year.

Product Description HVAC Mass Volume Header Plate
Capabilities and Processes Turret Press Blanking; Compound Forming; Prototyping; PPAP; SVPP; Custom Kit Packaging
Tightest Tolerance .003 inch hole diameter; 1 deg forming
Material Thickness .080
Material Used 5052 H32 Aluminum
Industry for Use HVAC
Volume 20K annualy
Lead Time KANBAN
Delivery Location Offshore
Standards Met RoHS; REACH
Product Name HVAC Header Plate
Project Scope Manufacture 43-inch long part that includes 5 compound bends
Mass Volume Large HVAC Component

Mass Volume Large HVAC Component

When a long-standing HVAC client modified a large component to improve performance, they came to Ajax for help in the fabrication. A critical link in a long supply chain, the 43-inch precision sheet metal part includes 5 compound bends.Quality problems would shut down the production line. We provide 20,000 high-quality pieces per year.

Product Description HVAC Mass Volume Header Plate
Capabilities and Processes Turret Press Blanking; Compound Forming; Prototyping; PPAP; SVPP; Custom Kit Packaging
Tightest Tolerance .003 inch hole diameter; 1 deg forming
Material Thickness .080
Material Used 5052 H32 Aluminum
Industry for Use HVAC
Volume 20K annualy
Lead Time KANBAN
Delivery Location Offshore
Standards Met RoHS; REACH
Product Name HVAC Header Plate
Project Scope Manufacture 43-inch long part that includes 5 compound bends
Solenoid Shell – Progressive Stamping Electric Motor Casing

Solenoid Shell – Progressive Stamping Electric Motor Casing

Our client relies on Ajax to provide just-in-time inventory to its offshore manufacturing facility, without resorting to expensive air shipments or jeopardizing a complex supply chain. In addition to providing cost-effective inventory management, we devised a three-hit punch press operation to replace the drawn over mandrel (DOM) tubing the client previously used. The redesign saved more than $1.00 per part.

Product Description Electric Motor Solenoid Casing
Capabilities Applied/Processes Progressive stamping custom packaging
Tightest Tolerance .005 inch (Hole Diameter)
Material Thickness 10 GA (.134")
Material Used HRPO Steel
Material Finish Zinc and yellow plating
Industry for Use Refrigeration
Volume 75K annually
Lead Time Kanban
Delivery Locationk Offshore/Caribbean
Standards Met Customer supplied print and solid model
Product Name Solenoid Shell
Project Scope Re-engineered from DOM to progressive stamping. Custom cell packaging.
Curved Architectural Framing

Curved Architectural Framing

Applying Lean Principles to a new customer’s precision stamping challenge, Ajax reduced production time from a month to a single day. Orders placed by 11:00 a.m. are manufactured, packaged and shipped by 5:00 p.m.While quantity of production for the progressive die stamping has grown to meet the customer’s increasing market share, quality has remained at 99.9%.

Radius Track

“Ajax doesn’t start to produce the product until they get the order. All non-value-added lead time and inventory have been completely eliminated,” said the president of Radius Track. “It has helped us to manage business issues like capacity, storage, and human resources. Our cash flow is not tied up storing finished goods. That’s a huge business advantage.”

Product Description Precision Progressive Die Architectural Component
Capabilities and Processes Tooling Design; Prototyping; Progressive Stamping; Custom Packaging
Tightest Tolerance .005 inch Hole Diameter
Material Thickness 20 GA (.036 inch)
Material Used G60 Galvanized
Material Finish Unfinished
Industry for Use Architectural Construction
Volume 30K annualy
Lead Time Same Day
Delivery Location USA (multiple destinations)
Standards Met LEED
Product Name Curved Large Component Architectural Framing
Project Scope Redesign Process Flow to Reduce Production Time; Labor and Inventory
Appliance Door Hinge

Appliance Door Hinge

Our client is saving more than $250,000 a year since Ajax took over the manufacture of this bottom hinge almost 20 years ago. Our continuous improvements in materials selection, tooling and production automation have eliminated heat treating, deburring and manual pin insertion.We achieved fully automated assembly with 0 PPM field failure.

Product Description Mass volume appliance hinge with progressive die stamping
Capabilities Applied Processes;Design; prototyping; pin insertion done in progressive stamping die
Tightest Tolerance .003 (Hole diameter)
Material Thickness 10 GA (.135")
Material Used Grade 50 HSLA/HRPO
Material Finish Zinc and clear (RoHS compliant)
Industry for Use Appliance
Volume 800K annualy
Lead Time 1-3 days
Delivery Location Midwest U.S.
Standards Met RoHS
Product Name Appliance door bottom hinge
Project Scope Reduce material gauge and increase strength for piece part cost reduction.
Design Work Material selection; tooling re-design
The Black Box Mystery Fabrication Project

The Black Box Mystery Fabrication Project

When our customer saw our redesign, which cut their part cost nearly in half, they immediately said yes–and swore us to secrecy. That’s why you won’t see a photo or product description here.

Beginning with a 22 gauge component that the customer was post-painting, we value-engineered a new, one-piece design with a proprietary forming and fastening system that eliminated welds. The new design enabled gauge reduction to 24, a one-pound weight reduction per part. A pre-painted finish eliminated powder coating. The product, completed in a single work cell with fewer steps, added $200,000 a year to the customer’s bottom line.

Product Description Black Box Capabilities Applied/Processes; Engineer; design; prototype; custom equipment and tooling
Tightest Tolerance .005" (Hole Diameter)
Material Thickness .050"24 GA(.023")
Material Used Pre-painted G40 Galvanized
Material Finish N/A
Industry for Use Commercial Construction
Volume 60 000 annual
Lead Time Same day
Delivery Location Midwest
Standards Met LEED
Product Name Black Box
Project Scope Reduced material gauge; eliminated welding; eliminated painting; developed work-flow center to reduce inventory and labor
Design Work Material selection; custom equipment and tooling; manufacturing design