Metalforming suppliers are facing unprecedented challenges in today’s marketplace. As capital becomes scarce, and competition for business increases, the impact of a die crash or production run of bad parts could make the difference in whether they survive. Companies must protect their most critical assets, the presses and dies. Presses, dies, and various press room automation systems are the lifeblood of the supplier, and their costs can run into multiple millions of dollars in capital investment.
Sensor-driven error-proofing and die protection programs reduce downtime, ensure production is maximized, and prevent costly capital equipment repairs. Sensor implementation can prevent most die crashes and defective parts production if utilized correctly.
The vast majority of expensive press and die damage occurs due to failure to implement or the misapplication of sensing devices through a die protection program. There is a relatively inexpensive way for metal formers to protect their most critical assets in terms of dollar value and revenue creation. Stamping companies need to focus on two main areas to reduce costly repairs and production:
Feed-in and feed-through: You have to ensure the metal is in the press before the start of the cycle, and that it is feeding through properly. Once the cycle has completed, you must make sure the finished part is out of the stamping area. The type of stamping you do will determine the various points where you will need to incorporate sensors.
Part and slug ejection: During the stamping process, scrap material will be left that needs to be removed before the next cycle. Failure to ensure this will leave material inside the press, which can affect product quality or cause significant damage to the press, die, or both.
There are multiple additional processes within the press operation that can improve overall operational efficiency, but the two above should be the first steps toward implementing a successful program.
Multiple sensing devices can help you meet these requirements as well as a variety of suppliers and options you can choose from. It is essential that your personnel are trained on the various sensor technologies, and you are aligned with a supplier that understands the industry, your processes, and the variety of dies and materials you produce.
Many suppliers can provide you with sensing parts, but only a few are industry experts and can serve as both a consultant and parts supplier. You may need to invest a little more to get the expertise necessary to implement a sensing program upfront. Still, it will pay dividends for years to come if you focus upfront on the products that will reduce the downtime related to premature component failure or misapplication of sensor components.
Also, since most suppliers outsource the design and build of their dies, it is critical that your sensor solution partner is involved in new die design, with both your internal team as well as your die supplier. In addition, successful die protection programs entail rigid specifications for die sensing to help reduce their spare parts footprint and maximize the performance of their sensing devices.