allison transmission cascade system

For the past 25 years, Iowa Engineered Processes Corp. has been refining and improving the Cascade Deburring and Cleaning System. We research, secure and than apply the latest technology in our Cascade Systems so that you can deliver quality products for your customers.

How can Cascade positively impact your bottom line? The four links to your left will connect you to Success Stories of how Cascade has helped others achieve their goals. You too can achieve success with Cascade.

Check out some of our Success Stories and then call to set up your free test processing to prove out the Cascade Deburring and Cleaning System. We can make a difference in your operations and improve your bottom line.

allison transmission logoBefore Bottle BrushBottle Brush DeburringIowa Cascade Deburring

Allison Transmissions is one of the world’s leaders in the design, manufacture and sales of automatic transmissions for trucks, buses, off-road and military vehicles. They are in this position because of their willingness to aggressively pursue innovation in the development of new concepts and to progressively address manufacturing issues.

The Problem: Allison recognized they had a problem with the cleaning and deburring of transmission control valve housings. Allison was using a multi-staged method for cleaning and deburring parts. Their process consisted of washing and blowout, burnish, burr, and yet another wash and blowout. After this process was completed, there was a 100% part inspection for burrs, dirt and shavings. “Countless hours were spent reclaiming discrepant material.”

The Cascade Solution: Since 1991, Allison Transmissions has been using the Iowa Engineered Processes’, Cascade System to clean and debur transmission control valve housings. Allison now has a 98% “Good As Is” ratio with remaining 2% requiring only “1 rework.” Allison’s own data, as illustrated in the graphs below, relates the overwhelming positive impact of the Cascade System.

ellesco logo

Founded 30 years ago Newcastle, UK-based Rotary Power, part of the British Engines group, is a market-leading manufacturer of hydraulic pumps and motors equipment. Its wide range of products is aimed at a diverse group of demanding applications and includes pumps and motors with up to 125cm3 displacements for the chemical and processing industries through to hydraulic motors used in heavy industry with capacities up to 16,000cm3 displacements. For Rotary Power, the quality of the finished item is paramount and the removal of burrs and other sharp edges is seen as vitally important to the manufacturing process. The traditional method of removing these features was to hand-fettle, which is both time consuming and inconsistent. “Due to the nature of some of our castings and the complexity of the cast cavities it could take up to 45 minutes to deburr one component,' says Steve Holt, Rotary Power's Production Manager, 'We also ran the risk of damaging components and, worse still, scrapping a part and losing all the value added up to that point.'” This situation was compounded in recent years by the increased volumes and the greater complexity that was being designed into the pumps and motors.

During the evaluation process it became immediately apparent that this was the right process for us,' confirms Holt. The machine has had an immediate impact on our business with productivity increasing dramatically and the previous bottleneck, caused by manual deburring, has disappeared completely. Quality has also benefited, with not one part being rejected since the machine was installed. We are now confident to issue parts from the Cascade machine directly to assembly. Throughout the evaluation process the key issues were quality and consistency, the dramatic reduction in cycle times being an added bonus.

The previous 45 minutes required to hand deburr has now been reduced to between 10 and 12 minutes, which includes the integral washing process and load and unload; although cycle times can be as low as five minutes, depending on component and process requirements. A further benefit, that also improves component throughput, is the fact that multiple components can be loaded to the simple, fabricated, fixtures.

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seong  shin precision logo

Seong Shin Precision

THE PROBLEM: Seong Shin Precision Co, Ltd. (SSP) is a South Korean manufacture of precision parts for the automobile industry. To survive in the highly competitive Korean automobile marketplace, it is imperative to consistently and economically produce high quality parts. On a monthly average, SSP manufactures 12,400 power steering pumps. SSP had been using a conventional shot blasting and hand deburring process for cleaning the pump housings. This process required four dedicated employees and resulted in a first time rejection rate of 40%. Numerous inspections and reworks were required to meet production quotas. Seong Shin Precision realized a change was needed in how parts are cleaned and deburred if they were to remain competitive, keep existing business and attract new business.

THE SOLUTION: Iowa Engineered Processes’ Cascade Cleaning and Deburring System was incorporated into SSP’s power steering pump production line and the results were immediate and profound. Utilizing robotic loading and unloading, project dedicated employees dropped from 4 to 1 and the time needed to clean and debur 12,400 parts fell from 592 hours to just 126 hours. One of the most impressive impacts was on the rejection rate. While the old process resulted in a 40% rejection rate, the Cascade System “achieved a rejection rate of almost 0%.” The Cascade System provides consistent, cost effective cleaning and deburring.

Part Flatness

THE PROBLEM: An auto parts manufacturing company submitted a bid to build transmission channel plates for a major automobile manufacturer. A critical production problem they were having was in maintaining part flatness after the deburring process. Various processes were unsuccessfully considered…shot blasting, ice blast and high pressure systems. These alternative processes were considered operationally expensive, inconsistent and did not correct the problem of warped channel plates.

THE SOLUTION: Prototyping was conducted on 100 channel plates using Iowa Engineered Processes’ Cascade Cleaning and Deburring System. Fifty parts were randomly selected for flatness testing with results decisively showing that Cascade will efficiently, economically and consistently deburr the transmission channel plates while maintaining part flatness. The Cascade System will process 10 channel plates per each 60 second debu