CASE STUDY 1: Tube Frame Distortion
CASE STUDY 2: Phosphate Rinse System
CASE STUDY 3: Door Hardware Coating Drum - Cost Savings
CASE STUDY 4: Fabrication and Machining of Reel Assemblies - Efficiency
A process equipment company in the area was having trouble with their current vendor of tube frames.
Their vendor could not keep the frames as square and accurate as they needed to be.
Their assembly people were having many problems due to distortion in these frames.
This client gave Palatine Welding an opportunity to bid on this project.
After listening to the client's issues, and assessing the problem, PWC identified the cause of the distortion.
The client was sending the frames out to be painted after fabrication and welding. The painter was using a powder coat system, which bakes the paint on in an oven. The baking procedure was distorting the frames out of tolerance.
PWC needed only to have the frames sent back after painting to be placed back into the weld fixtures and straightened before they were shipped to the customer.
The customer never had another problem with distorted or inaccurate frames
Palatine Welding was asked to quote a phosphate rinse system for a manufacturer seeking to install the system in their own facility.
When the drawings arrived, the materials of construction were listed to be 304 stainless steel materials.
We quickly realized that the materials of choice for this phosphate rinse system must be an error. PWC informed the customer that the S304 materials would not be a good choice.
Palatine Welding quoted the project to provide 316L stainless steel materials because of its increased corrosion resistance.
Despite this recommondation, the customer decided to have another vendor build the system from the S304 materials that were on the drawing due to the fact that S304 was considerably less expensive than the S316L that PWC was quoting.
Less then one year later, the customer sent Palatine Welding pictures of the totally decaying system, and asked that we build a replacement unit using the proper materials.
The unit with the proper materials is still in working order, and showing no signs of decay - 10 years later.
Palatine Welding was asked to fabricate a hardware coating drum to replace an existing drum.
The sample drum the customer supplied to PWC was manufactured using a standard sheet of perforated stainless steel welded to a frame.The customer needed quick turnaround for this drum.
The customer was going through a drum about every three months. The perforated stainless was breaking loose from the framework through wear and tear. The perforated made for a poor weld connection to the framework , and the drum was failing at these points.
With the customer's approval, Palatine Welding decided to fabricate the drum by making a custom-perforated sheet on our CNC punching machine, which would allow for clean weld connections to the framework. This increased the price of the drum, but made it much more durable.
The customer agreed to the increase in price, and now the drum lasts an average of two years , which in the long run has saved the customer in drum replacement.
Palatine Welding was asked to provide a Reel Assembly. It was manufactured out of three segments, each consisting of four welded parts.
The customer informed Palatine Welding that these segments were a critical area that caused extensive problems for past fabricators. These problems added assembly and machining time to the project.
Relying on the close relationship we have with our outside vendors, Palatine Welding was able to devise a way to fabricate and machine the segments out of a single piece of material.
The time to fabricate, assemble, and final machine the Reel Assembly was reduced. The problem experienced by past fabricators was eliminated. The cost was reduced due to manufacturing efficiencies.