"What do you mean we also have to leak test it?!" This is a rant commonly heard in the manufacturing industry because leak testing is so frequently regarded as a necessary evil and a non-value-added service. Non-value added means that the part undergoes leak testing in one state, and then exits the machine in the same state. Sure, we've proven its integrity, but there have been no additional pieces added or assembly performed, nothing to increase the value of the part as it moves through the machine. With a little creativity and forethought though, this doesn't necessarily have to be the case.
Our company has been performing leak testing on a variety of materials for years, and has a proven track record of success. We've tested everything from small components that would fit in the palm of your hand using low pressure pneumatic testing at 7 PSI to structural castings utilizing hydraulic leak testing at 2000 PSI. We've additionally done chamber testing for more complex parts. This is all fine and well but what about the added value? Well, a customer of ours recently approached us to discuss building a pair of machines for him. The first was a bushing press while the second was a leak tester for the assembled part. By looking beyond just the specific function and truly looking at the customer's needs, we were able to design one machine that was capable of performing both functions. In this case, it just so happened that the motion of pressing the bushings into this particular part was the same motion needed for the sealing plate of a leak tester. Our engineers were able to design a machine that would get twice the work out of the same motion.
Certainly, this part lent itself well to this lean leak testing process, and the fact is that not every part does. As you think about perhaps balancing your lines or combining machine functions with leak testing, keep in mind that the most promising applications are those in which the motion of pressing, clamping or assembly would be similar to the sealing motion required for leak testing. In this case, the lean approach worked and reduced labor content, floor space, and investment for our customer. Can your machine builder always do this? No, unfortunately not. But as a customer, you can always ask how you can get more for your money, and if your solutions provider is thinking lean, they can often find a way.
