More than three years ago, Om Galaxy Precision Mould Crafts Pvt. Ltd. became the first company in Vasai’s tooling hub to incorporate the Manleo Z-Setter into its operations. The precision mould company attests that the Z-Setter has significantly improved its machining process. This case study showcases how Manleo Designs facilitated the company’s transition from manual inspections to achieving precise accuracy with its Z-Setter.
Established in 1986 by Mr. Batchittar Singh Baddhan, Om Galaxy Precision Mould Crafts Pvt. Ltd. is a leading designer and manufacturer of high-precision plastic pipe fitting moulds. The company operates from a modern 75,000-square-foot manufacturing facility in Vasai and specialises in the production of complex moulds for elbows, tees, and couplings. Under the leadership of Mr. Opinder Singh Baddhan and Mr. Jyothish R. Nambiar, the company develops efficient solutions for both local and global markets, generating an annual revenue of $130 million.
The Challenge
In the pipe fitting industry, precise engineering is essential for tooling. Om Galaxy Precision Mould Crafts Pvt. Ltd. designs intricate geometries and tight tolerances to ensure optimal flow and leak-proof connections for components such as elbows and tees. This is particularly important when manufacturing moulds for industries dealing with chemicals, fertilisers, and more sensitive products like oil and gas.
Meeting these requirements involves addressing complex machining challenges, such as eliminating internal surface flaws, controlling thermal expansion during moulding, and ensuring precise dimensional control. For instance, they often encounter problems with deflection and distortion, which can affect the performance of the final component.
Mr. Opinder Singh explained, “Pipe fitting moulds, designed for components like elbows and tees, demand precise alignment and smooth internal surfaces to ensure proper flow and fit. We cater to industries and brands that deal with more stringent and sensitive products and offerings. In such cases, adherence to precision is critical.”
The company previously used manual methods such as tool bits and feeler gauges. Although these strategies worked well with trained operators, they resulted in inaccuracies, delayed setup times, and complex processes. For instance, one mould machining, which should have taken a few hours, took more than two days due to inaccurate machining and inspections.
“We struggled with manually setting and aligning tools, which was not only time-consuming but also prone to errors, even with the most basic pipe fitting moulds such as T-joints. Each tool change involved precise manual measurements, delaying our productivity and increasing setup times. The risk of human error was significant, resulting in irregular mould dimensions and frequent rework. Monitoring tool wear was difficult without real-time data, which resulted in premature tool replacements and inefficiencies. Our productivity and quality control decreased due to a lack of automation, and managing varying batch sizes was difficult and inefficient,” he elaborated.
The Solution
“In order to provide the highest quality and timely delivery, we had to seek out more sophisticated technologies,” said Mr. Opinder Singh, adding, “Nine years ago, we were the first in Vasai’s tooling hub to use the Manleo Z-Setter.”
The Z-Setter from Manleo Designs has completely changed the company’s machining process. It has automated the tool length measuring, which is necessary for precise tooling of various pipe fitting moulds. This improvement has enhanced workpiece setup, simplified fixing, and significantly reduced setup times. Consequently, productivity has increased, machining efficiency has improved, and tool life has been extended. All of these are necessary for producing high-quality pipe fittings.
The Results
After integrating Manleo’s Z-Setter into their machining operations, Om Galaxy Precision Mould Crafts Pvt. Ltd. has significantly improved tool measurement and machining procedures. The Z-Setter’s simple design and automated functions have streamlined machine setup and accurately established the Z-axis zero point. It continuously monitors tool height during machining and provides real-time feedback on critical measurements such as internal channel dimensions and multi-port fitting alignments. This constant oversight ensures strict design adherence and substantially enhances the quality of the produced pipe fitting components.
“The Z-Setter has radically changed our machining processes, especially for complex pipe fitting moulds with convergence, divergence, and multi-port setups—moulds that require more than the usual number of tooling operations. It accurately sets the height of the cutting tool relative to the workpiece or machine table, ensuring correct depth of cut and machining accuracy and assuring accurate tool alignment and positioning, which is critical for meeting the tight tolerances necessary in such complex systems,” stated Mr. Opinder Singh.
“Integrating the Z-Setter has been a game-changer for us. It has dramatically improved our tool height setting along with precision and efficiency. Its minimal maintenance requirements and impressive battery life add to its value. The simplicity of a battery change and the exceptional after-sales service from Manleo further enhance its appeal. The most effective aspect is that it includes contact detection, static or dynamic, mechanical & electronic Z-Setters, making it suitable for any machining environment,” he said.
“Given these benefits, we are planning to add two more Z-Setters to our operations. These advancements are crucial, as we continue to push the boundaries of quality and productivity in the pipe fitting industry,” he concluded.
Article and images courtesy Manleo Designs
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