Improving the Line
with the Right Line
Korean Auto Maker Finds Right Tools for Right Job a Winning Solution
The success of Korean made cars the world over is not a fluke or a once in a lifetime occurrence, it has to do with Korean companies coming together to produce highly precise and durable parts that can endure daily wear.
For Hyundai Sungwoo Automotive Korea, achieving excellence in creating and manufacturing high quality parts is not only their profession, but a passion that has propelled them into a world-class company that supplies only the best products used in every facet of casting, wheel and battery production.
Everything the manufacturer can be found not only in the two big Korean automakers, but also in big Japanese and German auto manufacturers and leading American railway and ship engine manufacturers.
To create these important automotive, ship building and railway parts, Hyundai Sungwoo Automotive Korea left behind the traditional cutting tool manufacturers from Sweden and Japan for cutting tools made in their home country; not because of patriotism, but because of the superior quality of the finished parts they provide to their global customers once they started using TaeguTec tools.
“Our customers, both in Korea and in the U.S. and Germany expect the highest quality parts and TaeguTec helps us create those parts,” said Machining Team general manager Lee Seung-woo.
Choosing the Top Slot
During a visit by TaeguTec Times to Hyundai Sungwoo Automotive Korea, Mr. Lee described the important process of creating bearing caps, which are used in piston engines to secure the crankshaft to the engine block.
By concentrating on using improved materials and quality workmanship as well as advanced designs, Hyundai Sungwoo Automotive Korea has helped its customers excel in highly competitive markets.
“By using TaeguTec’s special slotting cutter with TopSlot line inserts, we were able to increase productivity by about 20 percent and increase tool life by 75 percent,” said Mr. Lee.
The special cutter they used was developed by the research and development team at TaeguTec’s headquarters in South Korea. Hyundai Sungwoo Automotive Korea gave them a challenge, cut their cost and increase their productivity or else they will find another tool supplier that can do the job.
For the R&D team, the challenge was accepted and in no time, a special slotting cutter set that holds six cutters and 96 inserts was created to the delight of Hyundai Sungwoo Automotive Korea executives.
The TopSlot line of indexable slotting cutters covers slotting widths from 3 millimeters up to 26 mm wide and is available with either a fixed pocket or cartridge type cutter enabling the end user to adjust machining width while offering an economical solution due to its true three or four corner cutting edges and robust double-sided insert design.
Moreover, the TopSlot line offers various options and accommodates various machining conditions.
Yet, Hyundai Sungwoo Automotive Korea still had more to improve upon for them to quickly deliver their products to their customers all over the world.
Success Spawns Success
After seeing the success of the TopSlot with a special slotting cutter, Hyundai Sungwoo Automotive Korea presented TaeguTec with another challenge but this time for products made for their German customer. For this endeavor to succeed, Hyundai Sungwoo Automotive needed to tool an entire production line. Their goal was to easily, quickly and efficiently manufacture 200,000 bearing caps with the possibility of increasing production to 600,000 in the near future.
TaeguTec was up for the challenge and equipped all their machines with the right tools that not only cut on cost but increase productivity.
“We are very satisfied with their work, we were able to increase our productivity by 20-30 percent by not only having them suggest new tools but also new methods of manufacturing so we are very grateful,” said Mr. Lee.
For their grooving production line, Hyundai Sungwoo Automotive was looking for a grooving tool that can save on their enormous cost of not only the final produced product, but also help cut on the defects create during manufacturing due to the inefficient performance of the Japanese tool they were using.
With the parameters in hand, TaeguTec’s engineers went back to the drawing board and came up with another special tool based on the T-Clamp model. By improving the tool life, TaeguTec’s special order helped Hyundai Sungwoo Automotive save about $1,000 a month.
But the biggest challenge came when Hyundai Sungwoo Automotive asked TaeguTec to improve the production of their backing rings, which are used in the rail industry.
“ADI grooving is very difficult,” he said. “You cannot machine one grooving of one part so we tried many different combinations of tools.”
During their initial implementation process, Hyundai Sungwoo Automotive found that they could not machine one piece using one grooving insert with other cutting tool brands. “So since TaeguTec had success with our other requests, we asked them if they had anything to help us” cut the cost and increase the efficiency of production of a line that makes 200,000 pieces a year.
Another important factor was not only solving existing challenges that were not being answered with other popular cutting tool brands on the market, but also they needed a cutting tool company to look ahead and suggest a tool that will eliminate any future problems that could arise during the complicated grooving operation.
The request for change paid off and TaeguTec came with a brand new tool especially designed for their needs.
The TT6300 was developed for Hyundai Sungwoo Automotive’s needs and was later improved to become the TT7005, a grade especially suited for the machining of cast iron.
In the end, this new and improved grade helped the Korean manufacturing company reach cutting speeds of 180 meters per minute in the production of backing rings made from ADI, a cost saving of around $3,000 a month.
Hyundai Sungwoo Automotive Korea is not only open to finding new tools that help them achieve their goals, they also attend TaeguTec’s customer seminars in order to find newer and more efficient methods of production.
“The reason why we use so many TaeguTec products is simple, they have great technical support, their special tools are made quickly, are of the highest quality and their timely delivery,” he said. “Also, their tooling service is very good, suggestions are excellent. They offer the appropriate details for us to make the right decisions. In the end, we found the quality of their tools to be excellent.”