3 Solutions to Eliminate High-Volume Metal Stamping Defects. Methods for achieving quicker turnaround and zero defects

Transcription

1 3 Solutions to Eliminate High-Volume Metal Stamping Defects Methods for achieving quicker turnaround and zero defects Phone: Fax:

2 Introduction As global markets and business strategies evolve, there is an escalated need for quickly-produced large quantities of complex parts. Metal stamping is a fast and cost-effective solution for this large-quantity manufacturing need. While metal stamping is well suited for large scale production, there have traditionally been several challenges associated with the metal stamping of high-volume runs. Common challenges include tooling wear and tooling maintenance, long lead times for tooling development and inspection fixtures, fidelity to customers designs and specifications, and high quantities of defective parts for a variety of reasons, including an inability to inspect each part. Here are three of the most common challenges manufacturers face when producing high-volume runs, along with the quality solutions that ESI Engineering Specialties, Inc. has developed to overcome them. Phone: Fax:

3 Challenge #1:High volumes usually mean a high number of defects Solution: Multi-part fixturing for inspection resulting in a PPM rejection rate of virtually zero. At ESI, we have solved this common problem of part inspection for high-volume runs. We use multi-part fixturing that allows multiple parts to be inspected simultaneously. This ensures that no defective parts are sent to our customers. Inspection methods include coordinate measuring machines (CMMs) which use a probe to do a tactile inspection of each part, and machine visions systems which use imaging software to inspect parts. With our multi-part fixtures, we are able to measure and compare hundreds of dimensions in a matter of minutes. Our inspection methods guarantee the quality and fidelity of the parts we manufacture, no matter the size of the run. Our ability to inspect multiple parts at the same time guarantees that customers receive their parts, to print, on time, every time. ESI has manufactured projects with greater than 100 million parts without a single part per million defect. Working with ESI, results like this are not unique. Our multi-part inspection capabilities make it possible for us to repeatedly produce high-volume runs with zero parts per million defects. Challenge #2: Process does not output the part as it was designed or spec d. Solution: Custom-made gages that deliver instant feedback to the operator. Functional Gage #131 Place part into top section. Measures: Flatness, tab angles & mounting tab location Part pass thru freely Phone: Fax:

4 Challenge #2: Another challenge of manufacturing high volumes of parts is ensuring that the parts are produced in accordance with the original designs and specifications from the customer. Tooling wear and other causes can make the stamped parts lose fidelity during a production run. If these deviations from the intended design are not promptly recognized and fixed, they can create delays in production and delivery. ESI uses vision systems and custom-made gages that allow the press operator to inspect parts during production, while the parts are being stamped, instead of waiting until the end of the run. This provides our customers with a higher level of quality assurance. Custom-made gages are hardened and ground to ultraprecise tolerances to ensure that each part is manufactured to specification. By using a gage that can verify parts during a run, the operator is provided with instant feedback with regard to the form, fit, and function of each part. Any deviation in produced parts can be quickly recognized and resolved, resulting in fewer production delays. Challenge #3: High volume production wears down tools, resulting in production delays. Solution: Engineered tool steels that prolong die life. A third challenge involved with high-volume production is the resulting wear on tooling, the same wear that can cause quality issues if it is not identified and remedied immediately. High volume production runs can cause a fair amount of wear on metal stamping dies, resulting in the need for frequent tool maintenance and sharpening. Frequent maintenance leads to production delays and long turnaround times. At ESI, this potential problem is avoided by using the latest engineered tool steels in our dies, guaranteeing that our customers receive quality parts without production delays. The selection of tool steel has a major impact on how long a tool can be used to stamp parts before sharpening or more significant maintenance is required. Conventional tool steels are less expensive, but they are not able to maintain tool sharpness through millions of hits on tough materials like full-hard stainless. They require more frequent sharpening and maintenance causing production delays. ESI s stamping tools are made from the best tool steels available like carbide and CPM-15V. Carbide tool steels and CPM-15V are much harder than conventional tool steels and provide excellent toughness and wear resistance. Phone: Fax:

5 Challenge #3 By using higher end tool steels, we are able to decrease the frequency of required maintenance. This significantly decreases the amount of production time required for high volume runs. Where other kinds of tool steels may need to be sharpened after only 100,000 parts produced, at ESI we are able to extend this servicing to 1,000,000 parts or more while still maintaining quality, burr-free parts to print. About ESI ESI has more than two decades of experience providing high quality stamped metal parts for a variety of industries around the world. Our automated equipment can handle thicknesses ranging from 1/8 to.005 (4 mm to.1 mm). We can produce high-volumes of more than 20 million complex parts and we can do it without a single part per million defect. Our sophisticated solutions to common high-volume stamping problems guarantee that our customers receive the quality parts they need without delays. To learn more about how we can provide for all of your stamping needs, contact us today. Phone: Fax: