In the world of manufacturing, precision matters. Even the slightest variation in the size of a component can greatly impact the assembly and performance of the finished product. Having a variety of precision ball sizes to choose from makes the production process more efficient, but not all manufacturers have the capacity to stock and store all of these options. In these cases, developing a Step Size Precision Ball Program with a reputable company like Hartford Technologies comes in handy.

What are Step Size Precision Ball Programs?

Step size ball programs are projects where a manufacturer needs many many sizes of balls, rather than a specific size. This can be anywhere from 2-3 unique diameters, to dozens of diameters.

There are several reasons why a manufacturer may need a step size ball program, but generally it’s any application where the tolerance of the mating parts is not that exact, and the precision ball needs to take up the excess tolerance.

Some of the most common examples are,

1. Stamping produces a variety of tolerances when making rails and other components. Since stamping is not as precise, varying gaps may be left in the rails or other parts. Step size balls are used to take up the variable tolerances produced by the stamping process.
2. Successively larger balls are needed to expand the diameter of an insert/hole.
3. Inner and outer races in bearings often have tiny variations in the space between them. Step size balls are used to precisely fill this space.

Managing Step Size Ball Programs

Step size ball programs are difficult to handle, as a manufacturer will need to manage inventory on many sizes of balls. If any one of these is out of stock, an entire production line can go down until the right size is obtained.

Manufacturers often do not know what size will be needed until the mating components are manufactured. While improved precision on the mating components can help reduce this variability, the issue is difficult to fully eliminate with some processes.

Without the ability to predict ahead of time, manufacturers need access to all possible needed sizes with a short lead time. However, ball production is inherently a long process. Often taking 16 weeks or more for a new custom production lot of balls to be made. Waiting months for the right size part could spell disaster for a production line.

Ball production often requires large production lots to be made at once. This opens up the chances of obsolescence at the end of the program, and can balloon inventory levels and shelf space requirements to untenable levels. In addition, steel balls can rust if not properly stored for too long a period.

Overcoming Challenges A Step At A Time

Some ways to overcome the challenges of step size ball programs are to,

1. Develop a model for demand based on historical or predicted usage. The more a manufacturer knows about the variability in the mating components, the better they can predict future demand, and make intelligent decisions on safety stock.
2. Develop a robust inventory management system. This ensures that planners know exactly what sizes are in stock, how long it takes to replenish, and when to reorder a particular size.
3. Work with a quality manufacturer of balls with a proven record of reliability. Ask about their on time delivery, manufacturing lead times, minimum lot sizes, and if they are willing to keep safety stock for their customers so you don’t have to. Also ask if they have the ability to offload extra inventory at the end of the program, so obsolescence is not a concern.

Hartford Technologies and Step Size Ball Programs

Working with Hartford Technologies to create a Step Size Precision Ball Program has a lot of advantages such as: 

• Access to many unique sizes -  Hartford carries a broad range of step size precision balls in increments to suit your needs. By always having a variety of precision ball sizes on hand, you avoid having to halt production to special order a ball.

• Ability to adapt to the unpredictable - Even with not knowing what size you need until you start assembling your product. Hartford allows quick changing of releases so you can adapt to the unpredictable. 

• Avoid long lead times - Special ordering a precision ball can take 16 weeks. Hartford stocks all the sizes needed locally, so parts ship from stock. We refill our stock to ensure you always have the parts you need. 

• Low minimum batch requirement - Hartford can pull different sizes from one production lot, ensuring the smallest batches at economical prices.

• Less warehouse space needed - You get the benefits of having a wide variety of precision ball sizes without having to store them. 

• No leftover parts - Working with Hartford often allows Step Size Precision Ball Programs to end with no obsolescence at the end of the program. 

• Cost-effective and efficient - Off-the-shelf parts are often less expensive but not as precise. Step Size Precision Balls can accommodate these slight variations and make a precise fit without the cost of a fully custom component. 

How Hartford Technologies Can Help

Hartford Technologies manufactures a broad range of step size precision balls in increments to suit customer needs. Our precision balls can be manufactured in carbon steel, chrome steel, stainless steel, tungsten carbide, brass, glass and plastics.

Our Inventory Modeling Program monitors your process, usage, and history, and predicts trends that then control our manufacturing. As a result, the precision balls you need are always in stock.

Hartford’s Inventory Modeling Program allows customers to minimize inventory, precisely meet demand, and avoid excess stock. 

To discuss how Hartford’s Inventory Modeling Program can simplify your manufacturing process, contact us.