Many Models, One Custom Modular Fixture

Challenges

The more sizes in your product line, the more important it is to manage the time it takes for fixture changeover. In this case, the manufacturer of truck axle mounts had 34 part models, each with different X, Y, and Z dimensions. Because they operate as a high mix, low volume (HMLV) shop filling custom orders, they had to change over the fixture between nearly every single part. As a result, each changeover consumed valuable time and introduced potential errors in final part precision.

To keep up with demand while maintaining tight tolerances, they needed a more efficient approach. And that meant they needed precise hole alignment — that would be critical to ensure successful final axle assembly. All in all, this created a challenge that went beyond what a standard table and tooling kit could handle. What they needed was a purpose-built custom modular fixture.

Interested in reading more about how we can help HMLV manufacturers? Check out this Case Study in The Fabricator.

Solution

• Modular Table Base

• Adjustable axle simulator

• CAD Model templates

To address their problem, this manufacturer worked closely with our engineers. Ultimately, this collaboration would lead to a custom modular fixture that solved their toughest changeover challenges.

First, we designed a customized adjustable tube to simulate the axle assembly. As a result, it was now easier to hold parts in place and check the alignment of mounting holes. Next, our engineers designed CAD models for each of the 34 fixtures. Together with CAD drawings, the custom modular fixture, ensured accurate setups & allowed welders to quickly reconfigure the fixture for any part.

Result

Overall, welding their truck axle mounts on a Bluco custom modular fixture helped this manufacturer deliver higher-quality parts in less time. By pairing the modular table base with CAD templates, fixture setup and changeover are now fast and precise.

Meanwhile, the custom-built adjustable axle simulator maintained consistent hole alignment. It also served as a built-in quality check and made it easier to tip and unload parts for weld-out. Ultimately, the result was a streamlined assembly process tailored to this high-mix, low-volume environment.