The six steps to Jergens’ Custom Design and Build program begin with the decision, or need, for a custom solution and proceed to concept, cost and timing, customer approval, initiation of manufacturing, and ultimately delivery. The process presents clear steps and milestones for both parties to reduce development time.

“There are a number of key objectives we focus on when recommending these solutions to a customer, they include achieving the greatest machining access, maximized number of fixtured parts, and minimal changeover for the shortest cycle times possible”, said Omar Andino, Jergens National Sales Manager for the Workholding Solutions Group. “Our six steps simplify and clarify the process, providing a streamline collaboration between our folks and customer stakeholders”, Andino continued.

Adding quick-change to production boosts customer performance by minimizing change-over and setup time. Additionally, building a solution tailored to the exact needs of the component helps customers increase machining access, meet tight tolerances, shorten cycle times, achieve the lowest cost per part, and free up additional capacity. All of which supports high productivity as well as predictable and fast ROI.

Among the many Jergens products used are Ball-Lock® mounting systems, QLS tooling columns, OK-Vise® low profile edge clamps, and Zero Point System (ZPS). To produce the solution, Jergens relies on its decades of experience in engineering and manufacturing quick-change workholding systems.

Successes with these unique solutions can be quite substantial. One such example with an automotive component manufacturer involved changing the machine tool from a vertical machining center with a 4th axis rotary table to a horizontal machining center using a tombstone fixture. A second change was to replace manual clamping with a hydraulic system. Finally, an all-new fixture was created to make full use of the alternate machine and workholding. The results were a reduction of setup from 4 hours (on the high end) to just 25 seconds, in total taking 61% out of the overall cost to produce each part.

Jaw configurations and sizes that are not available from stock, including those with modified dimension or custom hard jaws are available with industry-leading turnaround time. Dillon short lead times save time and money by reducing downtime.

About Dillon Manufacturing

Dillon Manufacturing, Inc. manufactures a complete line of standard and custom workholding solutions including chuck jaws, chucks, vise jaws, soft jaws, hard jaws, collet pad jaw systems, chuck lubrication, and more. All products are made in the USA and Dillon is ISO 9001:2015 registered.

In addition to extra-long hard jaws, Dillon manufactures a full line of workholdig solutions which are available through their nationwide network of industrial distributors with industry leading lead times. Application engineers are available to assist with product selection.

Dillon Manufacturing, Inc. manufactures a complete line of standard and custom workholding solutions including chuck jaws, chucks, vises jaws, soft jaws, hard jaws, collet pad jaw systems, chuck lubrication, and more.    All products are made in the USA and Dillon is ISO 9001:2015 registered. 

About Dillon Manufacturing, Inc.

Dillon Manufacturing, Inc. manufactures a complete line of standard and custom workholding solutions including chuck jaws, chucks, vises jaws, soft jaws, hard jaws, collet pad jaw systems, chuck lubrication, and more. All products are made in the USA and Dillon is ISO 9001:2015 registered.

First among them will be additions to the company’s tooling columns made in the U.S.A. and constructed of single piece cast iron for maximum rigidity. These columns open horizontal machining potential and are a solid basis for custom workholding to suit specific customer needs. Several new styles include square, cross, and rectangular. Additionally, three mounting options are available – center pin, edge and ZPS – and the new columns are fully customizable. 

A second new product introduction is Jergens new 5 Inch Heavy Duty Machine Vise. Made of stress relieved ductile iron and flame hardened, the new vise provides very long usable life and predictable performance. They are also more easily moved and relocated by the operator due to the relatively small size and weight, but also ensure secure part holding and tight tolerances from general machining to high production. Additions include hardened jaw plates and a Ball Lock® fixture plate quick-change kit. The vise is also made in the U.S.A.

A third development is with the company’s Quick-Loc Pallet system. The new Quick-Loc 2 will replace the existing product line and features an improved design that engages pull studs inside the receiver. QL2 has a hardened coating for long life and durability. The range is compatible with all existing top tooling. Quick Loc pallet systems are used for fixturing on horizontal, vertical, and rotary operations. These low-profile adapters and pallets ensure repeatability of 0.0003″ and provide clamping forces of nearly 14,000 lbs.

Also included in these several expansions are two new ZPS installation choices for compact, light duty applications. SP140, the smallest clamping module on the market, and K02 pull studs utilize pneumatics and a mechanical spring in a small package. The combination offers quick-change solutions for vise or gripper jaws, electronic component manufacturing, packaging machines, medical technology, and automation.

To round out the new products, Jergens now offers a washdown tool. This simple device provides 360 degrees of spray using coolant flow to reduce machine cleanup time after a cycle. The ball cleaner washes chips off exposed surfaces, cleaning the machine at scheduled intervals which helps support long machining cycles and lights out machining periods when no operator is present. The washdown tool goes into the tool changer just like any other tool.

Another key area of focus is the company’s growing Custom Design and Build team. Through it, Jergens offers customer-specific solutions that are component driven and engineered for maximum machining access and minimum cycle time. These unique workholding solutions are supported by decades-long experienced individuals and dedicated facilities. The company’s proven processes ensure clear communication and short lead times. 

The full range of Jergens core products, including Ball-Lock®, ZPS, Quick-Loc, Fixture Pro, and OK-Vise® – will be on display throughout the exhibit.

About the Company

Jergens, Inc. is a global manufacturing leader of CNC machining workholding products. The company is ISO 9001:2015 certified and committed to helping customers achieve leaner, more profitable manufacturing, and continues to add products and engineered solutions for an integrated approach to “Manufacturing Efficiency”.

Dillon full-grip chuck jaws are made in the USA with industry-leading lead-times. They are ideal for high-speed machining, as well as precision boring, tapping, drilling, and finishing across virtually all industrial markets. In addition to brass, Dillon Full Grip Pie Jaws are available in 6061 aluminum, 1018 steel and cast iron.

These wrap-around type top jaws distribute more of the gripping pressure across the workpiece, reducing part distortion. Dillon standard and custom full-grip jaws are available in serrated, tongue & groove serrated, Acme serrated, and square serrated designs.

About Dillon Manufacturing, Inc.

Dillon Manufacturing, Inc. manufactures a complete line of standard and custom workholding solutions including chuck jaws, chucks, vise jaws, soft jaws, hard jaws, collet pad jaw systems, chuck lubrication, and more. All products are made in the USA and Dillon is ISO 9001:2015 registered.

Dillon full-grip chuck jaws are made in the USA with industry-leading lead-times, typically two weeks or less.  They are ideal for high-speed machining, as well as precision boring, tapping, drilling, and finishing across virtually all industrial markets.  In addition to 6061 extruded aluminum, Dillon Full Grip Pie Jaws are available in brass, 1018 steel, and cast iron.

These wrap-around type top jaws distribute more of the gripping pressure across the workpiece, reducing part distortion.  Dillon standard and custom full-grip jaws are available in 1.5MM x 60°, 3.0MM x 60°, 1/16 x 90°, or 3/32 x 90°serrations, American standard or tongue & groove, Acme, and square serrated key type mounting interfaces.

About Dillon Manufacturing, Inc.

Dillon Manufacturing, Inc. manufactures a complete line of standard and custom workholding solutions including chuck jaws, chucks, vise jaws, soft jaws, hard jaws, collet pad jaw systems, chuck lubrication, and more.    All products are made in the USA and Dillon is ISO 9001:2015 registered.

Dillon application specialists are experienced in workholding requirements for many industries, and are available to assist with chuck and jaw selection.

Like all Dillon products, their chucks are made in the USA in ISO 9001:2015 registered facilities.

About Dillon Manufacturing, Inc.

Dillon Manufacturing, Inc. manufactures a complete line of standard and custom workholding solutions including chuck jaws, chucks, vise jaws, soft jaws, hard jaws, collet pad jaw systems, chuck lubrication, and more.    All products are made in the USA and Dillon is ISO 9001:2015 registered.

Dillon Jaw Nuts, T-nuts, and Keys are available to fit all popular power chucks from 6” in diameter to 24” in diameter including Forkhardt, Gamet, Howa, Kitigawa, Matsumoto (MMK), Nikko, Pratt Burnerd, Rohm, Samchully, Schuck, SMW, SMW-Autoblok, and more.   Standard sizes are stocked for immediate shipment.  They are ideal for workholding applications requiring durability and high strength such as high-speed machining.

Dillon also offers special T-Nut designs and manufacturing service for custom workhlolding requirements.

About Dillon Manufacturing, Inc.

Dillon Manufacturing, Inc. manufactures a complete line of standard and custom workholding solutions including chuck jaws, chucks, vises jaws, soft jaws, hard jaws, collet pad jaw systems, chuck lubrication, and more.    All products are made in the USA and Dillon is ISO 9001:2015 registered.

Though the process of designing, selecting, and implementing the right fixturing requires extra time, talent, and technology, US manufacturers, and their customers are discovering that the additional investment pays serious dividends.

How Custom, Dynamic Fixturing is a Game Changer in American Manufacturing

For many major equipment brands, an inferior part can sabotage the performance of an entire machine, damaging both bottom lines and global reputations. In these cases, precision isn’t just an expectation, it’s a mandate. Thanks to today’s technology, improved surface finishes, and tighter tolerances are possible with the right people, tools, and strategies in place. One of the ways to achieve such superior levels of accuracy is by using specially designed fixturing for complex parts.

Fixturing or workholding devices are just as important to the production of precision parts as machining and tooling process. They keep part after part in position so that each finished product falls within a few thousandths of an inch of the desired specs. Fixturing selection also requires additional time and expertise that not every machine shop is cut out for — and that’s why US-based complex part manufacturers like Allis Roller are able to make a name for themselves in the niche of high tolerance applications.

President and CEO of Allis Roller, Dave Dull, put it succinctly: “Anyone can order a CNC lathe or robotic welder. Not everyone wants to take things to the next level with custom fixturing.”

At Allis Roller, custom fixture design is developed in collaboration with a full bench of engineers, die makers, and research and development experts. To produce the kind of precision results Dull expects at his operation, highly skilled machinists use stand-alone fixturing for many parts. This has required a significant investment in people and technology, but for this manufacturer, it has more than paid off in their ability to maintain customer satisfaction. It’s common in custom machining and welding for materials to shift unexpectedly, and adjustments have to be made in real-time in order to preserve tolerance. To keep production moving, Allis Roller’s fixturing team is available on the spot to make any necessary changes and maintain standards.

This is how operations like Allis Roller have been able to earn the loyalty of Fortune 500 companies and has allowed Allis Roller to purchase three new CNC Machining Centers for delivery by the end of 2019.

Custom, Dynamic Fixturing is Scalable and Technologically Advanced

Dynamic fixturing practices and methods are as diverse as the wide range of parts they serve. Depending on their specialty, some operations find it more cost-effective to provide a degree of customization without employing a full team of engineers. To streamline the manufacturing process, others will reuse custom fixturing for repeat orders once their customers have come to depend on a certain level of quality. The strategy used depends entirely on the needs of the application.

One method, known as modular fixturing, uses a system of interchangeable components designed to secure a given workpiece during a machining process. Modular fixturing is ideal for use in hole making equipment, such as horizontal or vertical machining centers. As CNC lathes become increasingly versatile machines, flexible solutions like modular fixturing also help to maintain quality from one unique part to the next.

This form of dynamic fixturing provides needed customization without creating custom workholdings for each new part. As long as the application doesn’t require a high level of custom engineering, modular fixturing systems can help streamline the process of machining precision parts. They can also be used for both high volume and low volume work to keep an operation moving from one job to the next with very little work stoppage or additional set up.

Using CNC equipment to fashion entirely custom fixturing can also streamline the machining process and improve accuracy because automated fixturings are able to produce exact tolerance per the customer’s specifications. The level of precision afforded by computerized fixturing also assures the customer that each new order will measure up to the same specs as the last. Consistent complex parts eventually power equally reliable machinery, allowing international brands to promise a high level of performance and longevity to their own customer base. For US-based machine shops carving out their own niche in a crowded manufacturing market, this benefit is key to their success with globally renowned equipment manufacturers.

Even with the benefit of the latest technology, some operations still rely heavily on people to produce the kinds of custom fixturing needed for more complex parts. For each new complex component, Allis Roller assembles a project team consisting of engineering, tool room, die making, and manufacturing departments. This team works together to ensure that the entire manufacturing process goes smoothly from start to finish, and that includes accounting for fixturing integration and adjustment. An individual welder’s skill is also imperative for achieving optimal penetration and a lack of inclusions in custom fixturing production. By combining the built-in adjustability and precision of CNC equipment with a high level of fixturing experience, complex parts manufacturers can maximize results, while keeping processes lean and cost-effective.

At the end of the day, the quality of the fixture dictates the manufacturer’s ability to reuse it down the road for renewed parts orders and directly impacts the customer’s bottom line. High tolerance parts machining forces manufacturers to strike a delicate balance between quality and speed, and the use of custom, dynamic fixturing is how it’s done.