Production from the perspective of an O-Ring
Today I would like to describe the manufacturing process in brief steps:
(Molded parts and other seals go through similar processes)
1
After the order is placed, I first wait for the ordered compound or the one kept in the climate-controlled warehouse, which of course must be inspected before processing.
2
Then the tool (mold) is prepared from which I will be produced.
Depending on my size, it consists of a different number of so-called cavities.
In any case, I am not alone in the tool.
The tool is scheduled into the production process and assigned to the machine on which I will later be manufactured. (After all, I don’t fit just any machine.)
So now I line up in the queue.
3
After my “colleagues” from other tools have gradually been processed, it’s finally my turn. (Luckily, I’m not the only one in production.)
MY tool is installed – the compound is brought to the machine.
The planned production process is programmed.
The machine starts up, heat and pressure are applied to the tool, and the first sample pressings are taken for inspection.
After approval, series production begins.
At regular intervals, so-called “skins” are sent to the laboratory for intermediate inspection.
4
Once I’ve finally been pressed, I undergo post-processing. Now things get cold.
First, I am deep-frozen with nitrogen in large drums so that the coarse rubber residues fall off. (Now I’m beginning to take shape.)
After that, I’m put into the next drum, where fine deburring is carried out using small stones or a granulate.
Of course, I have to wait in line everywhere, since there are only a limited number of these very expensive machines.
5
Now I am washed and cleaned.
6
Then it’s off to the heat. I am placed on flat trays or in a drum in special, computer-controlled ovens and tempered at 120 to 150° C so that I achieve the right consistency.
Sometimes I also receive a coating or am oiled.
7
Now comes the final inspection.
Either I am manually checked using random samples, or I am photographed several times by sophisticated cameras.
This is all fully automated – day and night.
8
In the laboratory, I am measured together with 10 to 50 colleagues from my batch. For example, the DVR and hardness are checked, or other values are determined according to customer specifications. All this is stored in a test report and in the computer system.
9
Then I am packaged with my many “fellow travelers” from this batch into bags and cartons. Particularly delicate colleagues may be automatically placed onto cardboard cores beforehand to prevent deformation during transport.
Finally, labels with a barcode are added for shipping.
Now I only wait for the freight carrier to take me to the customer, where I can FINALLY be put to use.
Well, that was a very long journey I had to make so that you receive the right quality and finish – and so that, for example, your faucet stays leak-proof.
You are also welcome to follow my “journey” with your own eyes.
I warmly invite you to visit the production. I would be delighted.
Yours sincerely, Michael Prosch and the APS Team