At the Manufacturing Innovation, Technology and Job Center in Cleveland, high school students learn metal stamping, laser cutting and other skills that prepare them for future success in manufacturing. The facility is now the headquarters for the Manufacturing Advocacy and Growth Network (MAGNET). People use approximately one-third of the building for manufacturing demonstrations and exhibits.
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The hope is that through hands-on experiences and training, young people will break down their preconceived impressions of manufacturing and develop the skills that will lead to well-paying careers. Elsewhere, some companies use technologies like virtual and augmented reality to train metal stampers. Trainees will benefit from seeing checklists and other supporting materials projected onto the equipment they use.
Education is a core element of quality metal stamping. Prioritizing education at the start of and throughout a person’s metal-stamping career is a practical way to improve outcomes.
Even the most skilled metal-stamping professionals cannot achieve their desired results if they continually struggle with environmental or equipment-related concerns. For example, leaders at one metal stamping company realized that their current shop layout caused issues that prevented employees from working at their best and raised the risk of injury.
The shop had used open floor space by storing dies in single rows. However, workers frequently rearranged the dies to get what they needed, which caused inventory damage and safety concerns. Changes occurred when the shop invested in a storage rack system that could hold 40,000 pounds of vertical storage per shelf. Getting tools off the floor expanded production capabilities and kept workers safer.
Quality metal stamping results also are easier to achieve if the tools are well-maintained. One option is to use smart sensors and algorithms that predict when problems will occur. Shop managers then have a window to respond before downtime affects production.
In one case, researchers from the University of Aveiro (in Portugal) designed stamping-press algorithms that measured 80 indicators of impending failure. Besides detecting problems, the technology suggested how to optimize production, and the results indicated that the algorithms could have made the press work nearly five hours longer, representing a vast productivity improvement.
Many business owners recognize that automation is the way forward for companies concerned about quality metal stamping outcomes. That’s because programming and algorithms allow equipment to perform repetitive tasks with fewer (or no) errors. Some users also combine digital algorithms with physical solutions, like robots.
Tesla is an example of the ways that robots can handle metal-stamping tasks. The electric car builder relies on the machines to stamp metal sheets for the front trunks of its Model Y and Model 3 vehicles.
Ford is another automaker that embraces automated metal stamping. Its newly opened South African stamping plant has a fully automated line, allowing the facility to process 272 tons of steel over three shifts at full capacity. The plant includes an advanced scanner to compare the perimeter and surface dimensions of each piece coming off the line to a 3D model stored in a database. While scanning took more than an hour with previous technologies, the current scanner does the job in under three minutes.
Automation is not a quick fix, but it can help manufacturers overcome numerous obstacles. Anyone thinking about implementing it should investigate what options exist and how to use them to enable continuous improvement.
Experts say an excessive number of parts tagged for scrap or rework are among the biggest signs a facility struggles with metal stamping quality. A stopped press is another concern because it can indicate issues with the quality of a just-produced product. However, ERP software can target these issues and others.
In today’s competitive stamping industry, manufacturers and customers often demand specific solutions to meet their production needs. With the rise of automation, however, standard equipment such as feeders, levelers, and other peripheral devices are sometimes insufficient to address these specific needs. When such situations arise, businesses need tailored solutions that optimize automation equipment and improve efficiency. This article outlines a customized solution developed for a customer in the stamping industry, focusing on connected control, cost reduction, and labor efficiency.
A recent customer inquiry highlighted a common issue in the stamping industry: the need for a production line that offers better integration, reduced costs, and minimized labor requirements. The customer wanted a stamping press, an NC servo feeder, and a forming machine all working in harmony, with the ability to be managed by a single operator. The goal was to reduce operational complexity and increase control over the entire process.
Our solution involved developing a production line with connected control capabilities, allowing for the seamless operation of all equipment through a centralized system. This innovative approach not only met the customer’s needs but also significantly enhanced overall productivity.
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The core of this solution lies in the integration of automation and efficient speed control systems. The solution included a combination of control systems and equipment enhancements to enable synchronized operations.
A key challenge in any stamping operation is maintaining a consistent and efficient speed throughout the stamping press. To address this, we introduced an induction frame positioned between the presses and between the press and the forming machine. This induction frame plays a pivotal role in controlling the speed of the stamping press by utilizing both upper and lower limit sensors. Here’s how it works:
To further streamline the operation, we integrated connected control into the entire production line. Through a central control console, the operator can manage the operations of all connected machines, including the press and the forming machine, with just a few clicks.
This connected control system allows one operator to oversee the entire production line, cutting down on labor requirements and reducing the chances of operational errors.
The NC servo feeder is a critical component in any automated stamping production line. Our solution upgraded the NC servo feeder to support multi-stage feeding and enhanced programmable capabilities.
The interconnected design of the production line was a major improvement, allowing for smoother transitions between each machine in the workflow.
Implementing a connected control system does not require extensive investments in new hardware. The only additional components necessary for this solution are the induction frame, induction rods, intermediate relays, and wiring. These are relatively low-cost additions, making the solution both affordable and scalable.
By integrating these components, the customer benefits from a low-cost implementation that optimizes production, reduces the need for multiple operators, and increases overall productivity.
In conclusion, the customized connected control system we developed for our stamping industry client is a perfect example of how automation can be tailored to meet specific production needs. The solution provides a highly efficient, cost-effective way to control a stamping press, NC servo feeder, and forming machine through a centralized control console.
If you want to learn more, please visit our website Stamping Automation Equipment Solution.