Reduce Costs, Streamline Production, Support Design Innovation with Custom Bearings

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Reduce Costs, Streamline Production, Support Design

Innovation with Custom Bearings

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q  This webinar will be available afterwards at www.designworldonline.com & email

q  Q&A at the end of the presentation q  Hashtag for this webinar: #DWwebinar

Before We Start

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Mike Sanotra Design World

Moderator

Mark Bos Vice President

National Bearings Company

Reduce Costs, Streamline Production, Support Design Innovation with Custom Bearings

Meet Your Presenters

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Reduce Costs, Streamline Production, Support Design Innovation

with Custom Bearings

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q  How to compare standard and custom bearings for the most cost-effective solution

q  Why custom bearings are not always cost prohibitive q  Design innovations that are only possible with a custom

bearing q  How you can use custom bearings to reduce costs and

streamline production from design to supply chain management

Overview

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q  Carry loads heavier than necessary q  Are capable of speeds in excess of

need q  Are manufactured to tighter-than

necessary tolerances q  Are manufactured from a few

standard bearing materials

Standard Bearings:

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q  More expensive than necessary q  Unnecessarily complex q  Over-sized q  Constraint to design innovation

Over-specified Standard Bearing

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Bearings Basics: Foundational Considerations

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q  Bearing type q  Loads and speeds q  Operating environment

The Bearing Selection Process

✓ ✓ ✓

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q  Thrust bearings are designed to carry primarily axial loads

Identify the Bearing Type

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q  Radial bearings are designed to carry radial loads

Identify the Bearing Type

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q  Angular contact bearings are designed to carry both radial and axial loads at the same time

Identify the Bearing Type

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Plain Bearings – no rolling elements

Define Loads and Speeds

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Ball Bearings – For greater loads & speeds

Define Loads and Speeds

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Needle & Roller Bearings – Large loads in compact design

Define Loads and Speeds

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Temperature

Operating Environment

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Corrosion

Operating Environment

UV Rays Acids Water or Sea Spray

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Contamination

Operating Environment

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q  Carrying capacity in excess of requirements? q  Requiring a change in the size or shape of the mounting,

mating components? q  Ability to eliminate or reduce number of components? q  Is the lifecycle of the bearing greater or less than your

product’s lifecycle? q  Large minimum order quantity?

Standard vs. Custom Comparison

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Opportunities for Value Engineering Through Bearing Customization

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Simplify Bearing Design — Reduce Bearing Complexity

Standard Thrust Bearing

Custom Bearing Retainer Only

Retainer

Race

Retainer

Balls/Rollers

Race

Standard bearings are made of a full complement of components. Custom bearings provide only the components needed for an application.

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Standard bearings are made of a full complement of components. Custom bearings provide only the components needed for an application.

Simplify Bearing Design — Reduce Bearing Complexity

Standard Angular Contact Bearing

Custom Angular Contact Bearing

Outer Race

Balls/Rollers

Seals

Inner Race

Grease

Balls/Rollers

Retainer

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Right-Size the Bearing — Achieve Optimal Physical Dimensions

Custom Size 10.5mm X 21.2mm OD X 4.5mm W

Standard 608 8mm ID X 22mm OD X 7mm W

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Integrate Additional Features

Over-molded Radial Bearing

Eliminate Components in your assembly q  Addition of a threaded stud for

mounting q  Simplify installation process q  Reduce purchasing and

inventory costs

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Integrate Additional Features

Stamped Angular Contact Bearing

Integrate More Exotic Features q  Include a ratcheting

mechanism q  Integrate cam arms for spin

control q  Change manufacturing

process from machining to stamping

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q  Stainless Steels- 300s, 400s, 17-4 q  Engineered Plastics- Nylon, Delrin, Acrylic q  Ceramics – Si3N4, Al2O3 q  High and Low Carbon Steels q  Bronze and Aluminum q  Exotic Materials – Titanium, Nitinol q  Protective finish – Plating, Passivation, Anodize

Proper Material Selection

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q  Alternative materials can stand up to tougher environments

q  Protective coatings can resist corrosion q  Proper material selection can remove the need for

additional seals

Proper Material Selection

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Combine Components into a Subassembly — Maximize Cost Savings and Assembly Efficiencies

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Combine Components into a Subassembly — Maximize Cost Savings and Assembly Efficiencies

4 Individual Components 4 SKUs/ Inventory Locations 4 Purchase Orders

4 Receiving Inspections 4 Supplier Development Processes 4 Quality Approvals

2 Manual Assembly Processes

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Combine Components into a Subassembly — Maximize Cost Savings and Assembly Efficiencies

1 SKU/ Inventory Location 1 Subassembly 1 Purchase Order 1 Receiving Inspection

1 Supplier Development Process 1 Quality Approval

0 Manual Assembly Processes

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q  Simplify the Design q  Right Size the Bearing q  Integrate Additional Features q  Choose the Proper Materials q  Consider a Subassembly

Bearing Customization Review

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Supply Chain Strategies for Additional Cost Savings

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Packaging Solutions q  Standard bearings have multiple layers of

packaging and boxes q  Require time-consuming removal of

bearings from layers of packaging q  Create large amounts of packaging waste

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Packaging Solutions Custom bearings can be package in custom trays that: q  Present bearings, properly oriented and ready to

assemble q  Reduce amount of packaging waste q  Reduce shipping and inventory costs

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Packaging Solutions Bearing Tray Redesign Yields $25,000 in Annual Savings q  New tray design increases bearing

capacity from 12 to 16 bearings q  30% Less boxes and trays equals

30% fewer pallets q  Customer reduced number of

pallets to ship by 30% q  Realizes a savings of $25,000 in

shipping costs

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Kanban .

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q  Reduce amount of inventory required q  Reduce minimum order requirements q  Allow for smaller shipment of USA made bearings q  Dramatically reduce lead time

Kanban

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q  Standard bearings may be an effective solution q  Custom bearings can reduce costs, streamline

production, support design innovation q  Know how and when to compare the options

Closing

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Mike Santora Associate Editor Design World [email protected] @DW_MikeSantora

Mark Bos Vice President National Bearings Company [email protected] 717-569-0485

Questions?

Reduce Costs, Streamline Production, Support Design Innovation with Custom Bearings

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Thank You q  This webinar will be available at

designworldonline.com & email

q  Tweet with hashtag #DWwebinar

q  Connect with Design World

q  Discuss this on EngineeringExchange.com