Revolutionizing the Transfer Die Industry for Maximum Production. STM Manufacturing, Inc.

Transcription

1 Revolutionizing the Transfer Die Industry for Maximum Production. STM Manufacturing, Inc.

2 Design/Build Case Study 7 station, 2-out, Support Member (servo press, servo transfer) Problems: Previous home-line runoff issues during initial setup: difficulty positioning transfer fingers, additional finger and bar clearances needed to hard tooling, press tied up during troubleshooting process, delays entering production, and loss of revenue for stamper and build shop.

3 Design/Build Case Study 7 station, 2-out, Support Member (servo press, servo transfer) Problems: Previous home-line runoff issues during initial setup: difficulty positioning transfer fingers, additional finger and bar clearances needed to hard tooling, press tied up during troubleshooting process, delays entering production, and loss of revenue for stamper and build shop. Solution: Transfer Simulation completed on die design before die is built, CAR Report communicates crash and clearance issues to designer so die design can be corrected, die is built and then shipped to stamper with setup instructions and transfer timing curves to enter production without issues

4 Design/Build Case Study 7 station, 2-out, Support Member (servo press, servo transfer) Problems: Previous home-line runoff issues during initial setup: difficulty positioning transfer fingers, additional finger and bar clearances needed to hard tooling, press tied up during troubleshooting process, delays entering production, and loss of revenue for stamper and build shop. Solution: Transfer Simulation completed on die design before die is built, CAR Report communicates crash and clearance issues to designer so die design can be corrected, die is built and then shipped to stamper with setup instructions and transfer timing curves to enter production without issues Results: No issues setting up die for Home-line runoff and production. Provided transfer timing and servo ram timing curves provide a high SPM rate. Increased revenue for stamper and build shop.

5 Design/Build Case Study 7 station, 2-out, Support Member (servo press, servo transfer) Problems: Previous home-line runoff issues during initial setup: difficulty positioning transfer fingers, additional finger and bar clearances needed to hard tooling, press tied up during troubleshooting process, delays entering production, and loss of revenue for stamper and build shop. Solution: Transfer Simulation completed on die design before die is built, CAR Report communicates crash and clearance issues to designer so die design can be corrected, die is built and then shipped to stamper with setup instructions and transfer timing curves to enter production without issues. Results: No issues setting up die for Home-line runoff and production. Provided transfer timing and servo ram timing curves provide a high SPM rate. Increased revenue for stamper and build shop. Since using T-Sim Solutions Transfer Simulation, our run-offs go a lot smoother. We address transfer interferences right up front in the design. We feel confident that when we send our tooling to our customers, it can runoff without transfer fingers crashing. Steve Lameyer STM Manufacturing, Inc.

6 Revolutionizing the Transfer Die Industry for Maximum Production. Matcor Matsu

7 Design/Build Case Study - Automotive Bracket, 2-out, mechanical press, servo transfer. Problems - Trouble positioning fingers, inadequate finger clearance, long initial setup time, back and forth shipping to add finger and bar clearances, difficulty achieving required SPM. Customer relationships strained, unexpected die build costs, delayed die delivery, press tied up during troubleshooting process, loss of revenue for everyone involved.

8 Design/Build Case Study - Automotive Bracket, 2-out, mechanical press, servo transfer. Input - Import 3-D design and Smart Press Template, enter bar locations and transfer specs.

9 Design/Build Case Study - Automotive Bracket, 2-out, mechanical press, servo transfer. Function - Auto Optimization finds the bottlenecks that limit achievable SPM. Example A: Gripper vs. die heel delays clamp in motion and timing.

10 Design/Build Case Study - Automotive Bracket, 2-out, mechanical press, servo transfer. Function - Auto Optimization finds the bottlenecks that limit achievable SPM. Example B: Gripper vs. aerial cam delays clamp out motion and timing.

11 Design/Build Case Study - Automotive Bracket, 2-out, mechanical press, servo transfer. Function - Auto Clearance & Clash Detection find all die errors to correct. Example A: Open gripper jaw clashes with lower die shoe and nitro. Output - C.A.R. Total errors found: 17 (6 clash, 11 clear.)

12 Design/Build Case Study - Automotive Bracket, 2-out, mechanical press, servo transfer. Function - Auto Clearance & Clash Detection find all die errors to correct. Example B: Cam punch clashes with stripper pad when die is in the open position. Output - C.A.R. Total errors found: 17 (6 clash, 11 clear.)

13 Design/Build Case Study - Automotive Bracket, 2-out, mechanical press, servo transfer. Function - Auto Optimization determines best transfer timing for HIGHEST SPM. Example: with enhanced panel control turned ON, 16 SPM using the transfer timing curves as shown. Output - Press Setup Report with all timing curves, Full Videos, press setup sheets

14 Design/Build Case Study - Automotive Bracket, 2-out, mechanical press, servo transfer. Results - Die ships one time to stamper with no re-machining required. - Initial press setup and home-line runoff are done in one shift. - Press operator has transfer timing curves for HIGHEST SPM. - Die enters production on time and panels transfer smoothly. Bottom line SUCCESSFUL HOMELINE RUNOFF HIGHEST POSSIBLE SPM RATE

15 Design/Build Case Study - Automotive Bracket, 2-out, mechanical press, servo transfer. Quote - "We've had fewer problems and frustrations with home-line runoff on projects run through your Transfer Simulation. What typically took a few days of press time is now done in a single shift. Our production rates have increased significantly. Mr. Andrew Szczepanski - Matcor-Matsu Bottom line SUCCESSFUL HOMELINE RUNOFF HIGHEST POSSIBLE SPM RATE

16 Revolutionizing the Transfer Die Industry for Maximum Production. L & W Engineering Holland, MI

17 Design/Build Case Study 6 station (2) out Bk Body Plr Inr Upr Problems: Difficulty getting new dies set up and running production, excessive time spent positioning fingers for best panel control, inadequate finger clearance requiring additional machining, setup personnel have to create timing curves in the press rather than running production.

18 Design/Build Case Study 6 station (2) out Bk Body Plr Inr Upr Problems: Difficulty getting new dies set up and running production, excessive time spent positioning fingers for best panel control, inadequate finger clearance requiring additional machining, setup personnel have to create timing curves in the press rather than running production. Solution: New die design ran through T-SIM to find bottlenecks and all crash and clearance issues. Auto-Optimization is used to create best timing curves for smooth panel control and highest possible SPM rate. Setup sheets showing exact finger positions are provided to setup personnel.

19 Design/Build Case Study 6 station (2) out Bk Body Plr Inr Upr Problems: Difficulty getting new dies set up and running production, excessive time spent positioning fingers for best panel control, inadequate finger clearance requiring additional machining, setup personnel have to create timing curves in the press rather than running production. Solution: New die design ran through T-SIM to find bottlenecks and all crash and clearance issues. Auto-Optimization is used to create best timing curves for smooth panel control and highest possible SPM rate. Setup sheets showing exact finger positions are provided to setup personnel. Results: Die enters production within four hours of start of setup (plant record). Die immediately achieves desired SPM rate, and as speed is ramped up press is maxed-out at 18 SPM. Panel movement is very smooth and controlled with no issues. Designer, Builder, Stamper are very satisfied. On our first project the die entered production in record time and with a high SPM rate. We are very happy with the results. - L&W

20 Design/Build Case Study 6 station (2) out Bk Body Plr Inr Upr Videos: Die within 4 hours of start of setup in the press:

21 Revolutionizing the Transfer Die Industry for Maximum Production. ODM Tool & Mfg. Co.

22 Design/Build Case Study Gullwing Bracket LH/RH Problems: Die in production with a low 13 SPM production rate. Excessive bar shake while panels are being lifted and pitched down to the next station causing panel control issues and sensor faults.

23 Design/Build Case Study Gullwing Bracket LH/RH Problems: Die in production with a low 13 SPM production rate. Excessive bar shake while panels are being lifted and pitched down to the next station causing panel control issues and sensor faults. Solution: Run through T-SIM to automatically find bottlenecks that hamper production. Auto-Optimize clamp, lift, & pitch motions for smoother panel movement, better part control, and increased SPM rate.

24 Design/Build Case Study Gullwing Bracket LH/RH Problems: Die in production with a low 13 SPM production rate. Excessive bar shake while panels are being lifted and pitched down to the next station causing panel control issues and sensor faults. Solution: Run through T-SIM to automatically find bottlenecks that hamper production. Auto-Optimize clamp, lift, & pitch motions for smoother panel movement, better part control, and increased SPM rate. Results: Bar shake significantly improved, better panel control with fewer sensor faults, and production rate increased by 23% (13 to 16 spm). *Adding trim station lift = 24 spm.

25 Design/Build Case Study Gullwing Bracket LH/RH Problems: Die in production with a low 13 SPM production rate. Excessive bar shake while panels are being lifted and pitched down to the next station causing panel control issues and sensor faults. Solution: Run through T-SIM to automatically find bottlenecks that hamper production. Auto-Optimize clamp, lift, & pitch motions for smoother panel movement, better part control, and increased SPM rate. Results: Bar shake significantly improved, better panel control with fewer sensor faults, and production rate increased by 23% (13 to 16 spm). *Adding trim station lift = 24 spm. We did not think the dies could be improved, but T-SIM made it possible to improve the SPM rate and make the die run smoother. - ODM

26 Revolutionizing the Transfer Die Industry for Maximum Production. Johnson Controls / Adient (Battle Creek)

27 Design/Build Case Study 15 station (2) out seat side member Problems: Project was only able to run at the min 15 spm press speed and transfer bars were shaking significantly during the clamp in and out strokes putting excessive strain on the finger tooling and bars. Frequent shut-downs from die crashes and sensor faults from panels out of position. Video showing problems in production (click or copy/paste):

28 Design/Build Case Study 15 station (2) out seat side member Solution: Reduce the G-Force in clamp motions to minimize the shake on the bars, Optimize the transfer to increase overlaps while maintaining min choke point clearances.

29 Design/Build Case Study 15 station (2) out seat side member Solution: Reduce the G-Force in clamp motions to minimize the shake on the bars, Optimize the transfer to increase overlaps while maintaining min choke point clearances. Results: Bar shake was eliminated, SPM was increased by 20% (from 15 to 18 spm) with no physical changes to the tooling. Video after T-SIM improvements (click or copy/paste):

30 Revolutionizing the Transfer Die Industry for Maximum Production. Dostel Makina

31 Design/Build Case Study 8 station 1-out Cross Member (mechanical press, servo transfer) Problems: Low production rate (10spm) parts were stamping at cost (no profit)

32 Design/Build Case Study 8 station 1-out Cross Member (mechanical press, servo transfer) Problems: Low production rate (10spm) parts were stamping at cost (no profit) Solution: Setup and simulated tooling with current settings, analyzed existing forces during part movement, and optimized settings to 18spm with minor tool modifications.

33 Design/Build Case Study 8 station 1-out Cross Member (mechanical press, servo transfer) Problems: Low production rate (10spm) parts were stamping at cost (no profit) Solution: Setup and simulated tooling with current settings, analyzed existing forces during part movement, and optimized settings to 18spm with minor tool modifications. Results: Increased production rate to 18spm (80% increase). Parts now stamping with above average profit margin. More press time available (increased capacity)

34 Design/Build Case Study 8 station 1-out Cross Member (mechanical press, servo transfer) Problems: Low production rate (10spm) parts were stamping at cost (no profit) Solution: Setup and simulated tooling with current settings, analyzed existing forces during part movement, and optimized settings to 18spm with minor tool modifications. Results: Increased production rate to 18spm (80% increase). Parts now stamping with above average profit margin. More press time available (increased capacity) "We like how simple T-Sim Solutions makes it for us to get valuable simulation results with step-by-step corrective action reports, and realistic video simulations. On our first project with T-Sim we gained 8 SPM! We went from 10 to 18 SPM, that's an 80% increase! - Can Yucel Dostel Makina

35 Revolutionizing the Transfer Die Industry for Maximum Production.

36 Design/Build Case Study First time user setting up and running T-Sim 4.0 (initial (2) projects) Purpose: To determine the amount of training required to efficiently run T-Sim software Key Points: Installed T-Sim 4.0 Full version on-site at GTD (V5 R22) Setup Login and Password to Online training tutorials and videos Spent (2-3) hrs. installing and giving a general overview of the software User Profile: Name: Nate Akin Company: Greenville Tool & Die Experience: 20 years in the trade with shop floor and design experience. Nate is proficient in using CATIA V5 but has had no training or experience on T-Sim products prior to this study.

37 Results (1 st Sim): (6) Station Transfer (Total time to complete = 3-4 days) Initial project setup time (including watching training videos) = 1.5 days Initial simulation (using pre-set transfer 20spm) ran and report completed in less than 1day Optimization of tool and re-check simulation ran. Key areas were identified in tooling where minor modifications would resulting in a 20% increase in production(24spm) = 3-4 hrs. It s easy to learn and use. Anybody can do it. I learn better watching the videos, versus having someone telling me or trying to read it. I thought the videos were very helpful. Nate Akin Greenville Tool & Die

38 Results (2 nd Sim): (6) Station Transfer (Total time to complete = 2-3 days) Initial project setup time = 1 day Optimization of tool finding key areas where minor modifications would improve production rate was completed and initial simulation was run = less than 1 Day Report Summary reviewed and Corrective Action Report completed = 1 Day I didn t realize how many more SPM you could get out of a transfer by optimizing it. Taking out small transfer bottlenecks make a big difference on your SPM. Nate Akin Greenville Tool & Die

39 Summary of Results: Completed (2) full transfer simulation with a re-run on one of them in less than 7 working days. No prior training or experience using T-Sim 4.0 before starting these projects Used on-line documentation and video tutorials to learn the software Even with 20 years experience in the trade, he recognized the value of running transfer simulations on these projects and better understands the importance of designing for production not just to make a good part.