Introduction

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Agenda

• HV Overview
• HV Capability
• Fabricated Parts
• Stage Tooling
• Progressive Tooling
• Tooling Design Guidelines
• Difficult Parts Tight Tolerances
• Example of HV Parts

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HV Overview

• 67 years of experience - company started in 1942
• 150 employees
• Plant built in 1992
• 125,000 square feet of capacity
• Over 100 stamping presses, 10 to 400 tons
• Complete metal stamper
• Short to long run
• Value added services assembly, prototyping
• ISO9001-2000 Certified
• Reputation for high quality

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HV Overview (continued)

• Stamp all material types
• 60 steel
• 20 aluminum
• 15 stainless steel
• 5 yellow metals
• Parts 36 x 72 to less than 0.5 to 0.5
• Complete tool room facilities (15 toolmakers)
• Complete design and engineering facilities
• Capacity 70, currently 1 ½ shifts
• EDI, CAD, Internet, MRP, JIT, 3rd party warehouse
• Ship worldwide

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HV Mission
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HV Strategic Direction

• Manufacture the Most Difficult Stampings
• Have the Strongest Quality Assurance
• Be Metal Stampings Experts
• Have Strong Customer Focus and Knowledge
• Expand Business Capabilities
• China, India
• Prototype Department
• Fine Blanking, Machining, TIG Welding
• Parts Washing, Laser Abilities

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Metal Stamping Industry Overview

• 11 Billion Industry
• Manufacturing is moving overseas although rate
  has subsided
• Many smaller stampers have gone out of business
  over last few years
• Material pricing is returning to previous levels

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HV Sales History

• 1999 15.1 million
• 2000 19.5 million
• 2001 19.6 million
• 2002 17.1 million
• 2003 16.3 million
• 2004 21.3 million
• 2005 22.3 million
• 2006 27.0 million
• 2007 28.3 million
• 2008 28.8 million
• Est. 2009 24.0 million

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Key Company Projects

• Implementing as much as we can (based on
  resources) to achieve our strategic goals and
  position ourselves for a successful future.
• We are busy continually improving!
• USA productivity up 7 annually on average
• Incentive Programs
• Employee Suggestion
• Safety
• Gross Margin
• Attendance
• Departmental

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Current HV Projects (continued)

• Brand New Trumpf 4,000 Watt Laser with 9 Shelf
  Tower System
• Added new 400 ton progressive press
• Added 6,000 more square feet new Ship and
  Assembly Mezzanines
• Completed 112 key management projects in 2008 to
  date
• ISO 90012000 no minors or majors in over 5
  years
• Implemented formal Operator Certification
  training program
• Continue to push cosmetic and aesthetic parts -
  implemented appearance part quality system
• Conduct annual supplier forums
• Market push for production machining, leveling,
  assembly
• Continue strong web site presence 1st page
  Google
• Focus on throughput on floor Master Production
  Board
• efficiency reports

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Current HV Projects (continued)

• 2009 Continuous Improvement Teams
• 1 Automate Inventory
• 2 Lean Manufacturing Improvement
• 3 Investigate New Processes and Acquisitions
• 4 Centralize Data and Automate Paper Process
• 5 Achieve ISO14001 and ISO90012008
• Sub CITs Training, Facility, HVs High End
  Branding

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Prototype Department

• Goal to create prototypes in 48 hours
• Procedures in place to allow this
• Dedicated personnel standing by
• Goal to capture new production business, new
  tooling
• Work with Sales to understand if just making
  prototypes
• Ability to increase margin through design change
  and consultation

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Harvey Vogel Service

• Design Assistance and Engineering
• Cost Reduction and Process Improvement
• Internet Collaboration
• MRP and SMP Systems
• 3rd Party Warehousing
• Kan Ban Systems
• J-I-T (Just in Time)

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Quality

• ISO 90012000 certified
• Complete inspection department
• PPAPs / FMEAs / First Articles
• Quality control plans
• Meets all regulatory requirements
• Plan to attain ISO 14001 Certification by 1st Qtr
  2010

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125,000 Square Foot Plant -State of the Art
Manufacturing Facilitywith over 100 Presses
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From small precision presses
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to large straight side presses
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up to 400 tons.
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CNC Machining Centers
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Wire EDM Machines
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Turret Presses with Robotic Feed
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Precision Laser Capabilities
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CNC Brake Presses
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Precision Leveling
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Value Added Assembly
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• Value Added Services
• Assembly
• Plating
• Leveling
• Deburring
• Double Sided Grinding
• Box Builds
• Hardware Installation
• E-Coat/Anodize
• Silkscreen
• Heat Treating
• Welding
• Labeling
• Bar Coding

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Employee Training Centerfor continual process
improvement
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Quality Assurance
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Types of Parts We Can Do For You

• More difficult, complex
• Tighter tolerances
• Appearance oriented
• Value added features

• Wide variety of industries
• Computer/Telecommunications
• Military Medical
• Enclosures, Covers, Chassis parts
• Recreational and Entertainment
• Food Industry
• Banking, Lottery, Cash Counting (Machines)
• Parts in almost every industry!

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Types of Stampings, Volumes

• Laser, Turret, Press Brake
• Prototypes (new department, purchased a new
  laser)
• Low volumes (less than 1,000 parts per year)
• Short Run
• Stage tools (in each press)
• 1,000 to 40,000 parts per year
• Less expensive tools, higher piece price
• Long Run
• Progressive tools (one press)
• 40,000 plus parts per year
• More expensive tool, lower piece price

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Low Volume PartsLaser, Press Brake, Turret Press
(pictured)

• Less Than 1,000 parts per year
• Prototypes
• Low volumes

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Medium Volume Short Run

• 1,000 to 20,000 parts per year
• Stage tools (tool in each press)
• Less expensive tools

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High Volume Long Run

• 20,000 parts or more per year
• Progressive tools (one press)
• More expensive tool, lower piece price

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Typical Fabricated Part
The blank was made on the turret press and the
forming was done using the press
brake. Quantities are low and tolerances are
generous.
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Stage Tooling

• Our Strength!!
• Typically for 1,000 to 40,000 parts annually
• Manufactured with tools built and maintained in
  house for life of part
• One time Engineering fee
• Can be put in die set if customer wants to own
  tool
• Usually one tool for each operation (e.g., blank,
  form, pierce, form)
• Shared die sets to reduce costs
• Large inventory of common form tools to save
  costs
• Used for contours machined from 3D cad model
• Less expensive tools, lower piece price than
  fabricated

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Stage Tool Compound Blank
Die
A compound blank tool will blank and pierce
simultaneously. We use the same tool design for
both large and small parts.
Punch holder
Blank punch
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Compound Stage Tool Mounted in the Press
Note the part exiting out the back
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Stage Tool Offset Form
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Stage Tool Gang Pierce
This tool pierces only. Notice the air lines to
eject the part for best run efficiency.
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Stage Tool Wipe Form
This wipe form forms 2 sides of a part
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Progressive Tooling

• Typically 40,000 parts or more annually
• Manufactured with tools built outside but
  maintained in house
• Charge for maintenance, customer usually owns
  tool
• One tool for all operations
• More expensive tool, lower piece price

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Progressive tool showing the punch holder, the
progression strip and the die holder
Punch holder
Progression strip
Die holder
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Progressive tool in the press running
Raw stock going into the tool
Completed parts exiting the tool
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Cost/Benefit Analysis for Type of Tool

• How many parts per year do you expect to run?
• Is the major cost in labor or material?
• What is the life expectancy of the part?
• How soon does the tool need to be paid off?
• Natural progression as customer/product grows
• Fabricated vs. Stage vs.
  Progressive
• Typically lt 1,000 vs. lt 40,000 vs. gt 40,000
• Part size, tolerances, of hits all play role in
  price
• Can use stage tools as back up for progressive
  tools

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This is a part that was 3 stampings and now is 1
stamping!
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Example of a part from startup to high run
Start up 3 piece assembly
Cost saving 2 piece assembly
Cost savings 1 piece stamping progressive tooled
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What Makes Tooling More Difficult/Expensive

• The supplier gets a drawing with no guidelines as
  to tolerance or critical features or dimensions.
• CAD drawing defaults to 3 decimals whether it is
  critical or not.
• Convenient dimensioning. i.e., dimensioning at
  the top of the form.
• Note You will save money by opening up the
  tolerances where you can.

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Design Guidelines

• The design guidelines are based on the PMA Design
  Guidelines Book, available from the PMA
  Association.
• The design guidelines are guidelines only. There
  are ways to make stampings that go beyond the
  guidelines. The guidelines and the suggestions
  offered tend to be the most economical way to
  make stampings.
• Key is to make stamping in least number of hits.
  
• The more generous the tolerances, will likely
  lower the cost.

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Complex Forms and Bends
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Difficult Part
This part is difficult because of the surface
finish requirements and the involved forms.
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Difficult Part
This part is difficult because of the surface
finish requirements and the involved forms.
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Difficult Part
This part is difficult because of the surface
finish requirements and the involved forms.
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Difficult Part
This part is difficult because of the forming.
The material is stretched beyond its elasticity
point and compressed causing wrinkling.
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Difficult Part
This part is difficult because of the relatively
deep draw, the embosses on the top of the part
and the large radius curve on the top surface.
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Difficult Part
This part is difficult because of the complex
forming done in three operations.
Dimensional features validated using a white
light scan.
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Dimensions are held from the shear edge of the
feature
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Hole to edge should be maintained

• The tool may break if the web is too small.
• The part may bulge if the web is too small.

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Irregular holes have a different blank to edge
ratio than round holes because of the geometry is
less strong.
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Holes to a form line should be 2 ½ material
thickness the form radius. If not, the hole may
distort.
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Dimensions to forms should be dimensioned at the
base of the form when ever possible.
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Height of a form should be R2.5T minimum
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Fastening Methods

• Spot weld
• Rivet
• Weld and grind
• Tox or Tog-L-Loc fastening

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Hardware Insertion

• Nuts
• Standoffs
• Special designed
• Floating nuts
• Studs

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Types of Material

• Cold Rolled Steel
• The most common material that we stamp
• Thickness .010 to .250
• .030 to .090 is the mid range that stamps well .
  Thinner and thicker are done all of the time but
  the tooling is more expensive
• Zinc, anodize, E coat, and paint are common
  finishes.
• Stainless Steel
• Tougher than cold rolled steel
• The tonnage is about 1 ½ times cold rolled steel
• Laser cuts well, forms well
• Use annealed temper when ever you can
• Passivate or degrease.

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Types of Material (continued)

• Brass
• Blanks and forms similar to cold rolled steel
• Tin is a typical coating
• Copper
• Blanks well. Tonnage is similar to cold rolled
  steel
• Forms can fracture with small form radius.
• Tin is a typical finish
• Aluminum
• Easy to blank - tonnage ½ times cold rolled
  steel.
• Forming varies with the type and temper.
• Anodizing or painting are typical finishes.

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Examples of HV PartsPrecision Leveled
Platefor food service industry
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Box Build with Multiple ComponentsATM Machine
CPU Chassis
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Aftermarket Gearshift Assemblyfor Hummer? SUV
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Computer Chassis for Military

• 8 metal stampings
• 3 aluminum extrusions
• 50 aluminum rivets
• Developed custom riveting equipment to
  significantly reduce assembly labor
• Lightweight construction

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ATM - Stuffer Drive Assembly

• 4 metal stampings
• 5 plastic components
• 2 drive belts
• 2 foam w/teflon wear surfaces mounted on springs
• Drive mechanism and other various hardware
• 100 testing fixture

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Computer Parts Isolation Frame

• Complex load arm assemblies mounted to machined
  aluminum frame
• Tight tolerance on every component to unsure
  success

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Internal Oil Sield for ATV Motor

• Complex forming
• Strengthening and anti-vibration features
• Worked with engineering building prototypes and
  multiple designs to optimize performance

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ATM Part Lower Stop Plate

• Made from high carbon steel, extensive heat-treat
  process utilizing specialized fixtures
• Post zinc plated
• High volume progressive tooled
• Constant LCC sourcing pressure

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Data Storage Filler Panel

• Stage tooled
• Nickel plated front bezel jointed to pre-plated
  panel with tox-lock (no fasteners)
• Riveted assembly of ejector levers
• Silk-screening
• 8 plastic cable retainers
• EMI shielding

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Automotive Bracket Low Volume

• Stage tooled
• Complex forming
• Machining
• Welding
• Zinc phosphate and Black e-coat finish
• 100 gauging of critical features
• Egg Cell packaging

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Computer Part MCM Spring Plate Assembly

• Manufactured to the tightest tolerances
• Heat-treated and ground
• Rigorous magnetic particle inspection
• Black e-coat finish
• Assembly and barcode labeling

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ATM Part Transport Platen

• Laser cut blank
• Contour form for all louvers and axel openings
• 2nd contour form for all the shallow forms
  creating the arch eliminating several press
  brake hits for a much more uniform part
• Powder coated

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Conclusion How to determine if tooling is
necessary?

• Determine annual volume
• Perform cost/benefit analysis
• Move from fabricated to stage to progressive
• Simplify parts and costs by asking the right
  questions
• Choose correct type of process
• Stage tooling methods
• Eliminate overdone tolerancing
• Work to reduce number of hits
• Look for alternative less costly finishes
• Ask HV Sales Engineers for ideas push them to
  help you get optimal part!

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The Harvey Vogel Advantage

• Strong Quality Systems and ISO 90012000
  Certified
• Precision Engineering
• Experienced Engineers
• Strong Design Support
• Rapid Prototyping
• Advanced CAD/CAM Design and Systems
• Continual Process Improvement and Cost Reduction
• Just In Time System and Vendor Managed Inventory

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Thank You!

• For Quotations or Informationcall (651)
  739-7373

Or visit our web site at
WWW.HARVEYVOGEL.COM
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