Replacing three cast units with one simplified & saved money

AXIAM was able to cast, CNC machine, assemble and tolerance test all in house. A complete one stop shop

Processes used in this case study

DESIGN:

Process design
Product design
Tool design
Engineering design
Product testing
Jigs & fixtures

MANUFACTURE:

Tool manufacturing

Injection moulding

Reaction & composite moulding

High pressure die-casting
Low pressure die-casting
Shell (cronin) casting
Sand casting
Heat treatment

Sub-supplier management

FINISHING:

Linished
CNC machined
Alodine pre-treatment
Vacuum impregnation
Vibrated
Ball burnished
Shotblasted
Clear anodised
Hard anodised
Wet painted
Powdercoated
Hard coated
Hot foil stamped
Pad printed

Q&A:

Certificate of compliance (CoC)
PPAP, PPEP

SIR - sample inspection report

Continuous evaluation & verification

CP & CPK study
CMM

Verification & testing
Environmental management (RoHS)

ASSEMBLY, PACKING & DISPATCH:

Assembly

Pack & dispatch: NZ

Pack & dispatch: Export

Simplify

Total solution

Processes used

Fisher & Paykel: Izona Cook-top Aluminium Rings

Only the best will do for New Zealand’s Master Chefs, which is why the 2010 winner of NZ Masterchef won an Izona Cook-top as part of his prize package. The Izona cook-top blends the performance of gas with the style and easy care of a glass cook surface and is so innovative it has taken home an international GOOD design award and a Gold for best consumer product in addition to the Stringer Supreme award at the NZ Best Design Awards.

The sleek design of the cook-top is made exponentially cooler by the fact that the gas hub rises so smoothly at the touch of a button it appears to be magic. What is it that makes the movement seem so effortless? – An AXIAM made Camlifter hiding just below the surface.

Initially Fisher & Paykel approached AXIAM with the concept as a 3 part set, each part cast and machined separately, then assembled together. Upon studying the concept, AXIAM floated the idea of combining all 3 parts into one cast unit, which would then be machined and separated at the same time. This led to a substantial reduction in initial tooling costs and ensured that each part was a perfect match for the other two pieces of the set.

AXIAM was also able to offer a ‘one stop shop’ – Casting, CNC Machining (including separation) and then assembling the set into an operational lifter ready to assemble to the Cook-top. With the design of the cook-top requiring utmost quality and precision, tolerances and quality testing are equally stringent, meaning each cook-top operates as smoothly and seems as effortless as the next.

As this style of cook-top is a completely new innovation, there were no precedence to the manufacture of these parts. This was not a problem for the AXIAM design team who looked upon the project as an opportunity to create the best and be a part of an award winning product. Something which the judges of the world seem to have confirmed.

Customer: Fisher & Paykel Ltd

Product:

532541 & 532540 cam lifter 20 & 30 PU Assy, 20 mm and 30 mm camlifting ring set which controls the raising and lowering of the gas burners on the IZONA range of Cook-surfaces.