Part Quality
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Part-quality issues and missed production quotas can sink profitability in a competitive marketplace. These problems tend to reappear&#;due to stress, lack of training or hard delivery deadlines, companies struggle to find the time to solve the root cause of these problems. The challenge of workforce retirement drives companies to understand how to integrate new generations into the press shop and successfully drive culture change throughout the organization. Will Healy from Balluff Worldwide offers methods to systematically achieve operational excellence using best practices and technology to improve uptime and eliminate nuisance stops. Drawing on more than a decade of personal experiences, Healy presents successful philosophies to overcome challenges in metal stamping production during his presentation, Steps to Creating Operational Excellence in the Press Shop. When operational excellence is achieved, manufacturers find that they have improved their competitive position, reduced waste, eliminated die crashes and boosted productivity.
Implementation of an in-die part-measurement, die-adjustment and part-tracking system can result not only in 100-percent verification of critical part features, but also in significantly increased machine utilization, more-reliable die protection and reduced scrap rates. James Barrett from Link Systems presents In-Die Part Quality Monitoring and Automatic Tool Adjustments to help stampers learn practical methods to select, apply and integrate sensors and control systems in order to fulfill the accuracy and quality demands of today&#;s metal stampings.
Digital Solutions
The digital world is working hard to keep pace with advancing stamping technology. Examples include optical scanning technologies that capture and digitize dies and stampings in order to assess and properly modify the tooling; morphing solutions that enable rapid and repeatable development of compensated die surfaces; and software for sheet metal-formability, springback and die-kinematics analysis.
Digital solutions also provide benefits for reducing risk associated with tool buyoff&#;the culmination of a complicated process of engineering and building stamping dies. Product design, sheet metal type, die process, press line and other variables influence the outcome of all stamping processes. Kidambi Kannan from AutoForm discusses how software can be leveraged early in the design phase to estimate capability of the die and stamping process to identify early opportunities for corrective actions that manage cost and result in timely buyoff.
Die Estimating and Stamping
Procedures and technologies required to successfully price metal stamping dies are crucial to the success of any metal stamping company. Emphasis must be placed on improving accuracy, saving time and lowering costs related to die quoting. Jeff Bennett from Tool Planners walks attendees through a sample estimate, including quote request, production-part design, process feasibility, die-construction specifications and standard die-cost-estimating methods.
Also offered at FABTECH are several presentations on die design, including Engineering Principles for Progressive Dies, Evaluation of Progressive Die Strips, Deep Drawing Cylindrical Shells and Deep Drawing Box Shells.
Want more information on stamping press technology advancements? Feel free to contact us.
Finally, no matter the accuracy of the die quote or the precision of the die design and build, the process will not live up to expectations without the proper lubricant. Bob Anderson from Tower Metalworking Fluids will present Evaluating Your Lubricants for Performance and Safety, where attendees will learn what to look for when evaluating process lubrication, why evaluation is required and when it should be performed. Anderson also provides an overview of new lubrication technologies, corrosion-protection advancements, considerations for environmental health and safety, and methods of capturing trial data to evaluate the financial impact of a lubricant or process change.
The time has come to narrow the knowledge gap. See you at FABTECH! MF
Technologies: Management, Materials, Quality Control
Stamping manufacturing has drastically changed over the years, and technology has played a critical role in improving the precision, efficiency, and outcomes within this industry. The manufacturing sector of the United States has steadily grown over the years with no sign of slowing down, and stamping manufacturing is now critical for many major trades such as the automotive, consumer appliance, and aerospace industries. These are a few aspects of technology that have transformed the stamping manufacturing process:
The utilization of automated production lines has been a game-changer in the manufacturing world. By creating production lines comprised of multiple workstations operating in tandem with limited worker interaction, machinery can be programmed and customized for precision with a lower risk to workers. The other benefit of these automated production lines is that while each machine in the line works in tandem, each is independently programmed and can be debugged separately, resulting in a higher level of quality control.
Advanced simulation software has allowed stamping manufacturers to simulate each step in the stamping process, from die face design to blank shape and size calculations. Utilizing this software to adjust and develop designs and profiles, as opposed to resorting to trial and error, results in a more time-efficient and streamlined manufacturing process with reduced costs.
Quality control monitoring has been a major technological advance that has improved the efficacy of outcomes for stamping manufacturers in recent years. Statistical control systems and sensors are now able to monitor manufacturing in real time to constantly oversee production and processes, alerting manufacturers to any potential defects or flaws in products. Other technological advances that have greatly benefited quality control in the stamping manufacturing industry include 3D tool design and simulation to plan for quality control from the get-go and proactively identify potential design flaws. These types of quality control technologies have made stamping manufacturers reduce costs and labor related to recalls and defective products, increasing productivity in the long run.
With the long history of Bopp Busch, we have seen many advancements in technology. To be the best supplier partner to our customers, we have incorporated many of these processes and equipment over the decades. We have also supplemented our core stamping services with e-coating, toolmaking, general assembly, and design services. To learn more about Bopp Busch and our capabilities, contact us today.
The company is the world’s best stamping press setup procedures supplier. We are your one-stop shop for all needs. Our staff are highly-specialized and will help you find the product you need.