FandMmag.com |

Automation â?? in many pressworking shops, it's no longer just an option.

It's the engine, so to speak, driving today's ever-changing markets in manufacturing. To stay abreast with the competition in an ever-changing market, quick-die-change (QDC) systems answer the need for speed and flexibility.

Longer press uptime, increased floor space and the ability to adapt to changing production schedules are some of its perks. Automating die-cutting procedures improves part quality, reduces die-repair costs and increases production with more control over the production system, especially when it's integrated into an automated storage and retrieval system (ASRS). The cost and timesaving benefits of quick die change (QDC) applies to the smallest shops equipped with two or three presses to the largest plants with vast pressworking operations.

First, consider die standardization. Standard shut heights, clamping heights, clamping location, pass height and die location decrease setup times. To obtain standard shut heights, operators can easily use adapters, risers or simply add a shim stock.

Another option is to install a programmable shut-height controller. CIECO Inc., Clinton, Pa., offers the RamMaster, which automatically adjusts a press slide to 0.001-inch accuracy. Using a keypad, the operator can select dies by job number and tool-code identification.

Clamp height is adapted by welding or bolting clamping blocks to the dies. By placing the clamp locations in a standard configuration so the slots or clamping surfaces correspond with every die that runs in a given press, a shop spends more time stamping parts instead of changing and adjusting clamps between each run.

Uniform die location makes setup even faster, ensures longer life for dies and improves part quality in progressive-die applications. Standardizing the die setup allows close evaluation of the procedures required to automate the process so the die setters can choose the most suitable path for integrating the new system.

A standardized stamping system using powered die-carts installed in the Chrysler's Sterling Stamping Plant, Sterling Heights, Mich., reduced changeover time from eight to 20 minutes. The system allows all the carts on a line to perform push/pull operation at the same time using a "domino" format — the old and new dies are changed in three minutes. Because the dies no longer swing through the air and are supported from below, they are safer for operators and equipment.

"The die carts provide much better control of the dies during the changeover process," says Robert Schreiber, Sterling's automation engineering manager.

Die-setting personnel need a good understanding of how to handle setup. The team should make adjustments while the machines are idle and while the machines are stamping parts, with a constant focus on improving production time with the new system.

For QDC to happen, organized prestaging must also happen. If anything, prestaging should make the best use of floor space. Personnel should prepare dies logically on their carts or lifts to ensure presses are running at maximum capability. Precise prestaging streamlines operations, eliminating time spent changing and adjusting die equipment. The production staff must use their time wisely during machine downtime, so they can make adjustments not anticipated during initial setup.