Custom Hydraulic Manifolds

• CUSTOM (adj): Made to personal order, or doing work only on order .

• HYDRAULIC (adj): Operated by the resistance offered or pressure transmitted when a quantity of liquid is forced through a small orifice or through a tube.

• MANIFOLD (n): A pipe fitting with several lateral outlets for connecting it with other pipes

A custom hydraulic manifold is all of the above, but it is also so much more. A custom hydraulic manifold is like a printed circuit board (PCB) in your computer. The multi-layer interconnecting conductors in the PCB are like the construction holes in the manifold. The hydraulic valves are like the chips that plug into the board. The in/out logic created by either PCB or manifold can be defined in schematic form. In the hydraulic manifolds case, however, a certain volume (gpm) of hydraulic oil under pressure (psi) is used instead of electric power. Screw-in cartridges or slip-in logic valves (with electrical or mechanical operators) are installed into or onto the manifold to control the flow of oil or its pressure. The electric valves incorporated in the manifold are controlled (on/off or variable rate) by some kind of electrical control device. In this way a large heavy device requiring tons of force to move can be safely and easily controlled and operated by means of a simple electrical device like a switch.

Sub plate mounted (electrical or mechanical) valves are also used to control the logic in the manifold and likewise the flow of oil to/from the ports. These ports are connected to a hydraulic power source, tank, or the working devices. Some type of hose or tubing is used to route the oil.

Because we are talking hydraulic oil here instead of electricity, an M&W manifold is made of metal strong enough to withstand thousands of psi of oil pressure at a particular flow rate, and is machined specifically to execute a designed-in control logic, which is unique to your application. This is where the word CUSTOM really comes into play.

Buying a custom manifold is NOT like buying a new shirt. A custom manifold is much more complex. A manifold is like the brain, which controls all the logic. Like the brain it is complex but powerful. A custom manifold is a high precision-machined metal body that may incorporate more than 200+ complex high tolerance diameter (+/- 0.001") multi step bores, threads, cavities and ports all of which are absolutely mission critical. Hydraulic pumps, electric motors, fittings, hoses, cylinders, motors, actuators, machine elements and the CUSTOM HYDRAULIC MANIFOLD: in short everything in the hydraulic system is part of the complex science of Mechanical Engineering. Many complex factors must be considered in the design to enable the correct functionality of the manifold. This is why M&W engineers and service staff are part of the solution. We'll help you incorporate the right parts for a high performance manifold solution by giving you 1st class technical service help.

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Getting Started

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Delivery

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M&W Express™ (Rush Orders)

M&W has some of the fastest machining capacity in the world within our facility ready to serve you. M&W also has the ability to create an application for you very quickly and get it run on one of those fast machine tools. It's not just one area that is streamlined, but ALL our processes are fast tracked to rush your manifold to you ASAP. All M&W systems work together to minimize wasted time and effort. Computerized shop control allows M&W to track your manifold instantly as it makes its way through various manufacturing processes to completion. M&W already runs 24X5 to shrink delivery time. M&W will do everything possible internally to insure quick normal delivery, while still maintaining tight quality process control. If this is not adequate however we will quote M&W Express™ expedited deliveries.

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Blanket Orders

11. Any request for change or cancellation must be made in writing and will be acknowledged by M&W fax.

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Shipping

Typically aluminum manifolds can be shipped UPS if size allows. Larger aluminum as well as ductile and steel manifolds are typically shipped common carrier. If you have a preference for particular common carrier you use for discounted transport, please specify this on your order; otherwise M&W will ship via most cost effective carrier. If extra packaging such as special wood crating etc is desired for larger manifolds please specify when ordering. Typical shipping would be on heavy wood pallets with 44 rated lb cardboard packaging with steel banding. UPS shipments typically go in 61 lb rated heavy cardboard boxes sealed with gummed tape. All types of UPS and FedEx services are available including FedEx Same Day (by scheduled airline). All freight charges are F.O.B. Cedar Rapids, IA.

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Prices

What do your prices include?

Normally quoted prices will include everything including engineering, approval drawing, tooling, coatings, plugs, orifices and packaging. In very special cases when M&W does not have the tooling or it must be special ordered specifically for the individual order there may be a special tooling charge. All quoted manifold prices are subject to change after 60 days from date of quotation.

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Terms

What are M&W's payment terms?

All quoted products are shipped net 30 days on pre-approved account, FOB Cedar Rapids, IA. Overdue accounts will be assessed a carrying charge. If there are problems developing with your account or unresolved issues here they need to be communicated ASAP. We know unforeseen things happen. M&W will be as reasonable as is possible under the circumstances, but you absolutely must communicate with M&W ASAP. If in doubt call: always!

Non-approved accounts will be shipped COD or must be pre paid by certified check. Call M&W Accounting Dept with questions.

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Warranty

What is M&W's product warranty?

M&W Custom Hydraulic Manifold Limited Warranty Policy

a) M&W Manufacturing Co (M&W) warrants the products herein described, so far as the same are of M&W's own manufacture, against defects of material and workmanship under normal use and service for a period of 12 months from date of shipment. This warranty does not cover ordinary wear and tear, abuse, misuse, over-loading, altered products, improper installation or application, use of improper fluid, or materials not of the M&W's own manufacture.

b) The obligation of M&W under this warranty shall be limited to the repairing and replacement, F.O.B. M&W's plant or allowing credit at M&W's option, any part or parts which may prove to be thus defective, provided the Buyer gives M&W prompt notice of the defect or defects and inspection, if required by M&W, confirms the defect or defects. It is expressly agreed that this remedy of repair, replacement, or credit, at M&W's option, is the exclusive remedy under this contract.

c) Equipment furnished by M&W, but manufactured by others, carries the original manufacturers guarantee. Expenses incurred by the Buyer in repairing and replacing any defective product will not be allowed except by written permission of M&W.;

d) M&W in its manufacture and sale of these products will assume no liability as to possible infringement of patents by virtue of the use of said devices in combination with other elements or structures. This sale is made on the express understanding that there are no warranties other than those contained in this agreement, and that there are no implied warranties, which extend beyond the description on the face thereof. In the event of breach of this contract by M&W, the Buyer shall not be entitled to consequential damages.

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Cancellation

What happens if I cancel an order?

Charges may be applied to cover the cost of the finished manifolds, engineering time, purchased materials and/or labor costs incurred at the time of the cancellation. Cancellation may also involve back charges depending on the total quantity shipped against previously quoted quantity prices.

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Returns

Contact Engineering to discuss quality related issues, and then obtain a Return Goods Authorization (RGA) number from Customer Service. Custom manifold returns are limited to warranty situations or modifications to exiting manifolds per customer P.O.

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Tooling

What do you mean by tooling?

Cartridge valves are commonly used in custom hydraulic manifolds. These cartridges are designed to screw into very precise machined holes with mating high tolerance, highly finished o-ring sealing areas and threads for holding the valve into the manifold. These special valve holes are called cavities and may be industry common such as C-8-2, C-10-3, C-12-2 or may be a special size unique to only (1) valve manufacturer such as a Sun T-2A cavity. These special cavities are machined with what is called a rougher to roughly form the cavity and then are finish machined with a very accurate multi-step form reamer, which is used to finish the hole. This is a very efficient way to accurately hold all steps in relation to the spot face and hold concentricity within manufacturers specification. Typically a female thread is also machined within the cavity to retain the cartridge as well as the multiple o-ring seal surfaces and o-ring entry grooves. M&W stocks literally hundreds and hundreds of these special form tools from all typical common valve manufacturers without which we cannot efficiently and accurately machine your manifold.

Special form tools are also used to machine standard size logic cavities for what M&W calls slip in valves. These slip-in valves are held into the manifold with a bolted down cover plate onto which may be mounted other actuation valves or solenoids.

Special porting tools are also used to create a wide variety of inch and metric standardized threaded o-ring ports. Other special grooving tools are used to create Code 61-3000 psi, and Code 62-6000 psi (4) bolt flange SAE ports where o-ring grooves are machined into the manifold.

A wide variety of special coated milling inserts called thread mills are used to rapidly create accurate female threads within custom manifolds made from materials that are difficult to tap with conventional taps.

Special tooling must also be used to insure the surface finishes and flatness of your manifold meet published manufacturer's specifications and standards.

So you can see it gets pretty "techie" when we're working on a complex custom manifold just from the tooling standpoint.

No worries. M&W has made a significant investment in stocking almost every conceivable combination of cavity and port tooling necessary to create your manifold. In very rare cases is it necessary to wait for special tools to be built. M&W is a custom manifold specialist and it really shows in this area.

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Gauging

What do you mean by gauging?

As noted in the "Tooling" FAQ many precision bores and threads are created within a custom manifold. It is very important to be able to measure and certify that the cavity bores and threads or sub-plate pads or ports are dimensionally accurate, traceable to national standards, and within the published engineering standards for the valve or port. Having an active gauge control program within M&W's internal Quality Assurance Program insures that all M&W gauges comply with required national standards.

We call this gauge calibration. If any M&W gauge is found when checked routinely, to not comply with standards, it is red tagged as defective and removed from service. Gauges that are found within compliance are also tagged as acceptable for service.

The same is true for larger machines such as the Coordinate Measuring Machine (CMM), which is used to check bore concentricity's, and locations that are complex or impossible to do manually. Everything at M&W must be traceable to standards to insure the accuracy of measurements made and the ultimate functionality of the manifold.

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Engineering Approval Drawings

Why do I need an engineering approval drawing?

Custom manifolds can be quite complex. It is very important for you to see and understand exactly what M&W is designing and is manufacturing to your order. The approval process prevents many mistakes from occurring before they become financially catastrophic. Often simple errors exist in schematics submitted for RFQ. M&W makes every effort to correct these errors during the design process and bring potential problems to your attention. An approval drawing is a very efficient way of communicating significant technical details to the purchaser of the custom manifold. It's WYSIWYG: (What you see is what you get). Check the approval drawing/schematic (sent to you as an e-mailed attachment) very thoroughly. You will need an AutoCad2000 or 2004 capable viewer to see and print out copies, as you need them. Many distributors share these simplified (externals only) drawings with their customers as a final pre-production check. Internal passages are NOT shown in approval drawings, but all external details will be shown as they relate to the schematic and ultimately the function and application of the circuit.

Obviously on a repeater this step may be eliminated. Schematics are shown in great detail on approval drawings. Once you are satisfied that the approval drawing is OK, you must fax or e-mail your approval to M&W. Without this approval we have no real way of being certain that what we are making is what you really need. M&W must be very disciplined about design details and revisions. What you see on the drawing and schematic will be exactly what you get. Obviously if there is an error on the schematic the manifold will be machined to include an erroneous passage.

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Testing

Why is it important for you to test your assembled prototype?

M&W will be supplying your manifold unpopulated. By that we mean it will not have cartridge valves or subplate mounted valves installed. Typically construction hole plugs (SAE or expansion type) are quoted installed and are noted as such on your quote. Each manufacturer tests each individual cartridge for function before shipment. Nonetheless, it is extremely important to conduct a proper test program to insure your assembled and populated manifold functions completely as desired before releasing it for production. Assembling the manifold with cartridges pre-lubed correctly insures proper backup ring and o-ring seal installation. It is important to adhere to valve manufacturer torque specifications as well during assembly to prevent valve malfunctions. Testing a new assembled prototype manifold in an organized manner and recording the results in writing insures all valves work well together properly within the manifold under realistic flow and pressure conditions. It also verifies correct functionality per the schematic and provides evidence of the same. It is very important to have baseline test stand qualification data to greatly simplify the process of troubleshooting problems that may come up down the road.

When you fax in a quantity order, not hearing or seeing otherwise, M&W assumes the prototype worked correctly as shipped and there will be no revisions necessary. Your quantity order is in effect your approval of the design prior to production. After production begins, all the costs of revisions to correct field problems get much more serious than the potential cost of correcting (or revising to include new functionality) a single prototype manifold.

DO NOT APPROVE UNTESTED APPLICATIONS. All M&W's quality control efforts have the goal of insuring that the production manifolds will replicate the 1st article inspected and approved prototype design to a very high degree of accuracy. After the initial prototype is approved M&W freezes the design. NO CHANGES CAN BE MADE by M&W (even if we wanted to make them) without your written direction and approval, which will result in a part number revision letter change and a quote revision to account for the changes in manufacturing processes. The revision approval drawing must be approved as well before the design can be released for production. If the revision is serious, it should be qualified by further testing.

You can readily see a disaster in the making, if testing is not properly done, assumptions are made, and the manifold is released untested for production. If you do not qualify your prototype by a complete test on the test stand or in conjunction with your customer in actual service, you are creating for yourself considerable financial exposure that is unnecessary. Any undesired feature existent in the approved prototype will be replicated into the production manifolds without question. A custom manifold is not an off the shelf item. The combination of the elements is totally unique and must be qualified through testing. Thus the beginning is very important. Do not assume, but simply test and rest assured you know exactly what you're shipping to the customer. It only takes a few hours and is a very inexpensive insurance policy against potential problems coming up down the road.

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RFQ

What do I need to include in an RFQ?

M&W will quote your application very quickly using custom semi-automated quoting software; the output of which will be thoroughly checked to prevent errors. In order to accurately create a quote however M&W must first create a simple engineering model of your manifold. Once your RFQ becomes a quote and then an order M&W will use this simple model as a base start point for your manifold design. Nothing will be wasted.

Thus M&W needs to know very basic information like what valves you proposing to use, plus pressures and flows. This will determine what kind of material must be used to handle the application. Typically M&W receives a schematic with the RFQ. This is the most efficient method of communicating significant engineering details. M&W is a manifold specialist and as such is familiar with almost all valve configurations used by most manufacturers. M&W also needs to know any special requirements you have relating to port and valve positions. Typically valves need to be located on a specific side and likewise ports etc. Perhaps you need electrolysis nickel coating on your ductile or steel manifold, or a certain color and specification of hard coat anodizing on your aluminum manifold. This is where you need to specify those details. It's actually very easy to do.

You can also go to the "RFQ Forms"; link for a faxable form or select the e-mailable "RFQ Form";. The 4th page of both forms includes a detailed "General Information Sheet"; with complete instructions on what's needed for an RFQ submittal. Fill it out by hand or on your PC and e-mail or fax it back. You may also use your own RFQ format. It's very easy to work with M&W. Our people are very knowledgeable and will help you if you have questions. They will assign an M&W Part Number to your application. This is a KEY NUMBER and must accompany any correspondence relating to the manifold. The other KEY NUMBER to note is your QUOTE NUMBER.

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M&W Quote Number

Why are a quote number and quote revision number important?

As noted above an RFQ will result in the generation of a M&W part number and then an M&W quote, which will include the M&W part number or your drawing number, material specification, size, coatings, plugs, assembled orifices, customer, quote number and quote revision level such as REV 1, date such as MO-DD-YY=4-21-03 and a quote number=Q-XXXXX. Note that the Q-XXXXX quote number does not change as the quote is revised but the new quote revision level, REV 1, 4-21-03 will reflect the change by noting a brief explanation of the changes made. It's simple to remember: drawing part numbers (see M&W Part Number) are revised by alphabetic letter and quotes by numeric revision number. Now let's look at a fictitious example: Q-13999, REV 1, 4-21-03

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M&W Part Number

What does an M&W Part Number mean?

It's very simple. All M&W Part Numbers are like YY-XXXXR DDD

All the digits have a specific meaning and are designed to be extremely easy to remember and accurately write or communicate verbally.

a) The YY digits are the last two digits of the year the part number was issued. Thus a part number issued in 2003 would read as YY=03

b) Next is the sequential number of issue of the application. Thus the 245th would be XXXX=0245. Obviously higher numbers were issued later in the year so this means something, just like the last 6 digits of the VIN number of your car, which denote the sequential production number of your actual car from that factory.

c) R=the revision level starting with no revision letter and then A, B,… to X. Thus when R=A this is the 1st official revision of the application.

d) DDD=the customer (distributor) identification code

These are always letters of the alphabet and help M&W rapidly identify you as the customer at a glance. While not actually part of the M&W part number the DDD distributor identification code always appears on all internal engineering documents and will appear on your application drawing. You will see your 3-letter distributor code on your first approval drawing and it will not change. Note that the DDD id code is not stamped on your manifold. For our fictitious part number we know that IRQ=Iraqi Fluid Power in Baghdad, Iraq

Thus our fictitious custom manifold part number would read:
#03-0245A IRQ
Pretty simple and a lot better than a meaningless part number like #610856A32.

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Revisions to M&W Part Numbers

How do I request a change in a previously M&W quoted or manufactured manifold?

It's very easy. Custom manifolds are designed and manufactured for very specific applications so changes are a fact of life. Often things change and quantities/pricing may need to be adjusted to reflect new realities. At M&W you need to request a revision to an existing part number. Any new order must note the revision level of the M&W part number that you are purchasing. Typically a revised quotation is requested to update the manufacturing cost of the requested changes either up or down. Note that you will also receive a revised approval drawing that you must approve before production can begin.

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M&W Date Code

What is the coded 4-digit number stamped on each manifold just below the part number?

The number that you see is the M&W date code. With this number M&W can track the manifold completely through our manufacturing process and tie it into a specific 24-hour shipment window date. This is a very important number. With it you can easily track for example a warranty or QC issue, or date inventory very precisely. This date code allows M&W to track the M&W custom hydraulic manifold back to it's historical process control inspection records which are on file at M&W. A fictitious date code example could be like: 0AD9

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Quality Assurance

How can I be sure of M&W's quality?

M&W is a "LEAN MANUFACTURER" who maintains rigorous in-process manufacturing control systems from RFQ, quote, quote revision, engineering drawing, drawing revision, incoming order, acknowledgement, scheduling, material purchasing and certification, CNC programming, machining tooling, set up, 1st article, in-process inspection, deburring, stamping, coating, assembly, final inspection, packaging and shipment. M&W is a custom manifold specialist with over 23 years of design and manufacturing experience. M&W is known for high quality and excellent service. M&W can handle your most complex manifold applications from (1) to (500) quantities. M&W can also handle your most complex SPECIAL 1st Article and In Process Inspection requirements. We can also accommodate small air manifolds or large size steel or ductile manifolds (1,500 lb +) with multiple (out of plane space saving) angle holes that do not require plugs. M&W's uses the very latest software, technologies and CNC (Computer Numerical Control) machine tools to create, track and maintain the quality of M&W manifolds. All measuring equipment used is calibrated to national standards. All process controls are utilized by highly trained/experienced M&W technical personnel.

M&W uses computerized REAL-TIME shop control, advanced (Computer Aided Design) with 3-D modeling, super efficient customized CAM (Computer Aided Manufacturing) automated CNC programming systems and advanced computerized CMM, (Coordinate Measuring Machine) all in the hands of talented individuals with experience. M&W is an industry-leading producer of "Built to Order" quality hydraulic manifolds with a proven successful quality track record. Learn why M&W offers you more value and better-documented quality than competitors.

M&W manufacturers your manifold so that it meets all valve manufacturer, SAE and Metric port specifications for accuracy. M&W is familiar with most common valve manufacturers standards as applied to screw-in or surface mount valve technology.

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Available Materials

What materials are available for manifolds?

M&W produces custom manifolds from aluminum, ductile iron, steel, stainless steel and some types of plastics. (See also FAQ on Castings) There are a wide variety of grades and types of each of these materials, which are used, depending on the need of the application.

Most commonly used aluminum (AL) for standard pressures (2500 PSI MAX) is 6061-T1, but stronger AL alloys such as 2024-T3 and 7075-T6 aircraft plate are also used for mid range pressure applications. Ductile iron (DI), #65-4512 is a very popular mid (2,500-3500 PSI) to high-pressure (5,000 PSI +) application material.

Many forms of steel are used including 1018 CF or HR if the manifold must be welded. Large extremely high-pressure applications typically use a free machining grade of plate steel machined specially from "as received" condition to eliminate the surface cracking that can be common close to the surface in heavy rolled plate.

Stainless steel is also used as needed, usually some form of 304. While quite pricey, there are some applications where stainless is the only answer. Space age plastics are used for pharmaceutical manifold applications. Bottom line: M&W has experience with a wide range of materials and can design and build your high quality manifold smartly, competitively, and quickly. M&W manifolds are built to LAST!

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Castings

Can M&W machine iron and aluminum castings for hydraulic manifolds and components?

Yes.  M&W machines many complex components that are basically manifolds but also have other features machined into the casting for filters, mountings and flanges. With the increasing popularity of castings this capability is being utilized by many of our distributors to offer their customers even more value.

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M&W CAD Capabilities

What type of computer aided design capacity is used?

This is an important question because M&W often has to use pre-existing CAD drawings obtained from our customers to create the CNC code needed to manufacture a manifold. You in turn will also have to possess the capacity to open and view the AutoCAD format .dwg approval drawing that you will receive from M&W by e-mail prior to the manufacture of your manifold.

M&W can import and translate drawing files generated by most common CAD systems. Call the M&W Engineering Dept if you have questions.

The ability to work from accurate existing CAD drawings saves a lot of time and money by eliminating the need to redraw the manifold. Most important to M&W is the actual accuracy of your electronic image file. At M&W we call inaccurate drawings pseudo or fake drawings. In other words the printed (eye candy) dimensions, holes and lines SHOWN on the drawing are NOT ELECTRONICALLY ACCURATE and in agreement to 0.0001 inch. This happens when someone revises a dimension but does not actually move the hole circle or entity to the correct dimension. When M&W imports your drawing we first must blow away all your dimensions. The CAM system that creates the CNC machine program that drives the tool does not read the dimension value you see but instead, and far more accurately sees the electronic position of the entity from its noted zero reference. You can see how this will lead to errors! The CNC machine will put holes in places other than those dimensioned locations. In this case M&W has to start all over and straighten out the drawing so that it is indeed accurate to the eye as well as electronically.

Many other factors come into play. Do you have an electronic image file of a 3-D model or is the manifold shown in the traditional orthographic projections of Top, Bottom, LH, RH, Front and Rear 2-D views the CAM system will need to see to create the code to create your manifold. It gets pretty "techie" so call with questions and we'll walk you through the process.

Obviously if M&W is creating the CAD drawing it will be output in true .dwg format which is M&W's preferred format. Why AutoCAD? Because it's like Kool-Aid, motherhood and apple pie: its very popular and available inexpensively everywhere. An AutoCAD generated drawing can be handled by just about anyone with an inexpensive viewer and laser printed for your own use.

M&W's CAD system is very special and can handle 2-d or complex rendered 3-d models. M&W's "world wide state of the art"; custom manifold CAD software is very powerful and can easily perform hole intersection checks, minimum remaining thickness checks, automated drill chart generation as well as a host of other useful features that are used to generate your manifold drawing accurately and quickly. Of course all of this is neat software of no use without talented and dedicated M&W engineer's with the experience to make use of these capacities. What is it worth to be RIGHT THE FIRST TIME?

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M&W CAM Capabilities

What kind of computer aided manufacturing (programming) capacity is used?

M&W uses a sophisticated computerized CAM system to convert the electronic image of the design created in CAD into CNC code that M&W's high speed machining centers can use. A similar technique is used to create DMIS CMM programs for inspections. As discussed in FAQ under M&W CAD Capabilities it is very critical that the electronic image of the design be accurate. Inaccuracy or incorrect formatting of the drawing is perhaps the largest problem M&W encounters when importing (NON-M&W) customer CAD drawing files. Once imported into the CAM system, M&W's powerful software is used to create the programs used to machine the manifold. Depending on the quantity, size and complexity of the manifold, multiple parts may be machined on multiple sides of the fixturing that accurately secures the manifold relative to the known reference system within the machining center. Additional features such as complex angle borings may be performed down inside various valve cavities and ports. (SEE M&W PLUGLESS™ DESIGNS THRU ANGLE MACHINING under "WHY M&W" link for details)

M&W's complex angle capacity eliminates expensive and labor intensive external plugs, the space they take up and the potential leak points they create providing a more reliable, space efficient, superior, cost effective manifold. Sometimes M&W is handling up to (15) separate reference systems simultaneously while machining a complex manifold with a 200+ hole count and multiple angle holes. It is imperative that the CAM system can handle the CAD system output efficiently while creating CNC code for a machine with designed for capacities. This is where M&W's specialized technology really comes to the forefront.

M&W has unrivaled "world class state of the art" capacity in this area. Tight integration of engineering and manufacturing at M&W is what we call our "M&W Systems Technology" and it ultimately proves itself by out-performing the competition. Bottom line: M&W has the capacity and technology to rapidly create your custom "Built to Order" high performance manifold very efficiently. M&W will specifically design your manifold to utilize M&W's special in-house machining capacities. Winning always requires extraordinary effort, but winning by being smarter is always fun. This is why we say it's never "just a manifold".

M&W manifolds are better by design, but not just the actual engineering design, but also better-designed and implemented processes and better process controls utilizing better "M&W Systems Technology". There is more to an M&W manifold than meets the eye, because a lot of things are being accomplished internally! This is why M&W believes we can offer you the customer more value. Our many long time customers agree.

Technology is a very important part of M&W's success story, Because it takes a substantial effort to continually employ all the worlds' latest technological innovations, M&W literally travels the world seeking the technology to push the envelope so that M&W can by design, out perform the competition. Champions care about one thing: winning. To win you must cross the finish line first. To get there first you must actually be faster and better. M&W's current success has been paved by the preparations of yesterday in a never-ending disciplined race against time to provide the best manifolds to the industry.

M&W can help you win! May we have the opportunity to work with you?

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M&W Machining Capabilities

What kind of size limitations exists for custom manifolds?

M&W has made a more significant investment in machining technology than in any other single internal process involved in the manufacture of custom manifolds within our factory. M&W literally has traveled the world in search for the fastest, most accurate, reliable and efficient machining technology that exists today. M&W has significant relationships with machine tool builders who we work closely with to insure M&W is at the cutting edge.

This requires a substantial commitment to not only having the latest equipment but also to insuring M&W technical personnel really know how to use it. Modern world-class machining centers are basically computerized manufacturing systems which M&W operates 24X5 in the race to complete product as quickly as possible. M&W employs a fleet of (15) major CNC's including multiple 400, 500 and 630 mm pallet machining centers with both 40 and 50 taper, 6K -14K RPM, 40 HP spindles and with extended matrix tool magazine capacity. These machine tools represent the very latest in machining technology with the average age of these tools being less than (5) years. These specialized machine tools also provide the unmatched manufacturing efficiency, accuracy and reliability that is required to provide demonstrated cost performance. The largest units can carry a manifold up to 2,650 lb in weight and 39.4 X 34.6 X 31.5" dimension. A significant investment has been made in fixture technology to insure a multi-sided complex manifolds can be held advantageously to insure maximum machining efficiency.

Rest assured M&W has the capacity to accurately and reliably machine your custom manifolds. M&W also has the Systems Technology in place to insure that our designs maximize M&W's unique machining capabilities and that product quality is maintained throughout the machining process. With 23 years of operational machining experience over 100,000's of hours, M&W has become a Machine Tool Specialist.

M&W also employs late model world-class high speed sawing technology to efficiently process raw material for manufacture. M&W also employs a significant investment in high speed and heavy twin milling capacity to quickly and accurately pre-size parallel sides of any aluminum, ductile or steel manifold efficiently.

Prototype manifolds are sometimes machined on DRO equipped conventional mills to speed delivery if programming for a CNC is not a feasible alternative.

M&W has always had a philosophy of doing things right. This is especially true with manufacturing assets. All equipment within M&W's facility from Toyota forklifts to our late model advanced high-speed computer network software and hardware and our workstations to washing equipment are modern. All undergo scheduled maintenance to insure continued reliability. Come and visit and you will see what we mean. We believe you can see the difference from the moment you step into M&W's facility. You will see evidence of discipline, good planning and quality process control in action.

M&W believes we must earn your business by offering more and we must be willing and motivated to serve you better than others.

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M&W Secondary Operations

What do you mean by secondary operations? Why are they so important?

General: At M&W, Secondary Operations are all those processes that are accomplished after the manifold is machined. These processes include, deburring, labeling (stamping if not engraved on a CNC during machining, final high quality (HQ) surface facing, washing, coating, inspection, assembly, final inspection (manual or CMM), packaging (palletizing or crating) and on-time shipment. When cross-holes are created by hole machining, burrs are inevitably created at the intersections of internal passages. It goes without saying that all such burrs must be removed to insure proper flow and the elimination of future contamination due to burrs breaking off under high flow situations.

While not commonly accorded as much attention by outsiders as the more "techie" automated Preliminary Operations such as CAD, CAM programming and CNC machining; Secondary Operations are extremely important. It may interest you to know that more labor is expended in Secondary Operations on a manifold than in Preliminary Operations. You can easily loose all the designed and machined value of the product by mishandling the manifold in Secondary Operations.

Everything about a custom manifold is important. Finish, size, location, cleanliness, assembly, number of HQ faced sides, shipping distance to customer, mode of transportation, type of packaging etc … all are examples of essential items that absolutely must be correct to result in proper field performance. Some manifolds are very simple and can be easily handled by hand, others are 2,000 lb plus and must be carefully handled to prevent scratching and packaged securely to insure quality on receipt. The following data walks you generally through the processes M&W uses to finish a manifold once it is machined. M&W spends more time and effort in Secondary Operations to absolutely insure your manifold is correct, than is conventionally envisioned. M&W is a manifold specialist and it shows.


M&W SECONDARY OPERATIONS PROCESSES

1. Once a manifold has been machined it enters what we call the SECONDARY OPERATIONS DEPT. Here the product receives all final deburring, stamping, washing, final inspection, assembly and packaging prior to shipment to the customer.

2. The first step in secondary operations is to remove all loose chips and debris with compressed air. This insures that the product is as clean as possible prior to being deburred. This makes all burrs and cross sections as visible as possible under inspection with portable halogen inspection lights that are used to shine high intensity light down each cavity, port or bore.

3. Any parts in the batch that are GREEN TAGGED are separated and returned for manual machine repair. Any RED TAGGED parts are scrapped at this time so that a complete accounting can be made as to total potentially acceptable parts per quantity originally sawed and squared. Once repaired and checked OK for compliance, the green tag is removed and the part may be treated as acceptable and placed with the good parts.

4. It may be noted that deburring really doesn't start after machining… but really begins in engineering or programming as we analyze the best manufacturing process to minimize deburring effort and maximize product quality on the machining center. This also involves in process inspections during machining to insure that machining processes are controlled tightly.

5. The product is then manually deburred using a wide variety of special hand and/or powered tools to remove all burrs remaining from prior machining operations. Sharp intersections are chamfered as well. The condition of each cavity is visually inspected at this time specifically looking for proper finishes and threads.

6. The outside of the manifold is filed and SCOTCH BRITED to improve the external surface condition. Special note is made of faced surfaces for sub plate mounted valves, rota-burring each sub plate port hole to a proper chamfer.

7. The manifold is then blown out completely and moved to the stamping area. A sample block is black marker labeled then inspected OK to drawing specifications, and released for final stamping. This is very important because stamping errors are hard to correct without causing damage to the product. Stamping MUST be done right the first time!

8. If the manifold must be faced for HQ sub plate mounted surfaces it is moved back into the machining area and these operations are completed. Each faced surface is checked with a portable Surface Tester for compliance with surface requirements on the engineering drawing in the process file that follows the job through all operations from sawing/squaring to final shipment.

9. Note that with our computerized shop floor data collection system we can trace the process through each step knowing who performed each step and signed off compliance.

10. An M&W date code is stamped on each manifold allowing it to be traced back to M&W and associated with its complete manufacturing records that are on file.

11. The manifold is then blown out completely and moved with process documentation to the wash area. Here the manifold is placed in specially rubber coated wash racks and washed in a high-pressure (2) stage automated washing machine. Manifolds are placed in the wash racks to facilitate liquid flow through the manifold for maximum cleaning action. A special liquid soap for use with aluminum is used in the first stage of the hot water based process. This soap is formulated not to burn or discolor faced surfaced and cavities. A 180-degree temperature rinse cycle is then performed with a rinse aid to leave the manifolds brightly clean throughout and ready for anodizing and /or inspection prior to assembly. A different washing machine must be used for heavy ductile iron or steel manifolds, as they must be treated with rust inhibitor during the second wash stage.

12. Note that some ductile or steel parts will be washed prior to deburring operations. The idea is to pass progressively through multiple stages to increase product cleanliness. Special techniques must be used with various lifting devices to safely lift and protect manifolds with multiple faced sides.

13. The person performing the operation then signs off documentation as evidence of compliance making note of quantity, shortages etc…

14. Once washed the manifold batch is immediately shrink-wrapped for transport into the clean room. Here it will be inspected before final assembly. If the batch is to be anodized or otherwise coated it is immediately packaged for shipment to the subcontractor who performs the treatment. The anodizer will check all threads with certified thread gauges prior to treatment. If anodizing is not performed correctly (over etching) the thread areas can be damaged resulting in oversize threads. In this way the subcontractor inspects and records/certifies that anodizing in no way damaged the integrity of the part. M&W receives a copy of each batch certification on receipt from the anodizer.

15. Once M&W receives the newly anodized manifolds they are processed through the clean room for inspection. We will again look at the finishes, threads, bores, stamping etc … to insure that the product complies with engineering specification in every way. In this way the product is repeatedly washed and inspected by different individuals each time progressively pushing cleanliness and product integrity higher. It is only with this type of care that M&W can achieve the very high level of quality required in hydraulic service.

16. Note that in every case the un-anodized manifold receives the same final-inspection processes that an anodized manifold would receive

17. Once inspected, the manifolds will be assembled per engineering drawing instructions. Plugs must be tightened to proper torque levels, expansion plugs driven correctly etc… The manifold must then be cross-inspected by a different individual on the team checking plugs etc… visually to prevent something from being missed. This seems easy until it is realized that some manifolds we routinely manufacture have more than (200) holes or cavities and many also have extensive orifice plug installation requirements. Such a complex manifold may require more than a single shift to properly inspect and comply with the required 1st Article Inspection Documentation.

18. The assembled manifolds are then packaged as required and correctly labeled externally with special M&W computer tags showing job number, p/n, qty, ship date requested, name of individual doing the packaging and count, the number of packages in the batch, and finally the customer name. The green shipment form is then also filled out which goes to the shipping dept. The order is then checked against the actual original order for correctness and then shipped as requested.

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LEAN Manufacturing

What is lean manufacturing?

LEAN is a method of manufacturing that eliminates waste, improves the quality of our manifolds and enhances value for our customers. Lean makes M&W quicker, more agile and more efficient and thus more competitive in our market segment. It is the foundation of job security at M&W. It's kind of like "Weight Watchers for Manufacturing Processes". When thinking "LEAN" M&W becomes extremely conscious of why we are doing each step in our processes as we seek to eliminate waste and enhance value for you the customer. The best way for M&W to help you win is by being "LEAN" so that costs are held low while quality remains high.

LEAN is not something you buy, install, flip a switch and it goes; it's a way of thinking, a philosophy that requires the conscious participation of all M&W's employee's.

LEAN is a way of harnessing the often HIDDEN power of people to focus on the execution of a good plan. M&W knows how to orient its people so they can execute their individual missions successfully, but always as part of the overall plan. It's not enough anymore simply to have new equipment. You really have to know how to organize and use it to win! Real values, high intelligence, organization for execution, mission planning, devotion to common goals, teamwork, personal discipline and attention to detail are considered the "Right Stuff" at M&W and help us help you win. LEAN manufacturing concepts provides the framework through which these pre-existing M&W values are applied.

If a LEAN M&W is doing it's job right we will show you how you can SAVE money on every application. Let M&W show you how you can still have high quality for a competitive price by increasing the intellectual content of your manifold design through smarter thinking.

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The following are M&W Trademarks: M&W EXPRESS™, MANIFOLD HELP™,
M&W PLUGLESS™, M&W CUSTOMIZED STANDARD™

M&W believes we have more value to offer you!
May we have the opportunity to work with you?