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Quick Die Change, 2nd Edition
You need quick die change for
economical small lots and just-in-time!
432
Pages · Many
illustrations · Over a hundred
expert contributors
Quick Die Change, Second Edition
pulls together various manufacturing concepts to
demonstrate how to achieve dramatic setup time
reductions. The book covers not only the basis of
changing dies quickly but many fundamental concepts of
pressworking that affect the correct changeover of
dies.
The book includes chapters on - economic order
quantity and just-in-time, training, acceptance,
involvement, and support from the workforce, diesetting
practice, die clamping methods, die parallels and die
locating methods, quick die change strategy, setting
progressive dies quickly and accurately, setup of
tandem line dies, operating dies at a common shut
height, decoiling, straightening, and feeding coil
stock, transfer press and die operations, press force
monitors, press safeguarding, ergonomics, training for
emergencies and preparedness, unsticking presses, and
die maintenance documentation and
tracking, economic order
quantity and just-in-time, training, acceptance,
involvement, and support from the workforce, diesetting
practice, die clamping methods, die parallels and die
locating methods, quick die change strategy, setting
progressive dies quickly and accurately, setup of
tandem line dies, operating dies at a common shut
height, decoiling, straightening, and feeding coil
stock, transfer press and die operations, press force
monitors, press safeguarding, ergonomics, training for
emergencies and preparedness, unsticking presses, and
die maintenance documentation and
tracking
Contents of Quick Die Change, 2nd Edition
1. Introduction - Evolution of QDC, Benefits of QDC
2. Basic Good Diesetting Practices - Review of die locating techniques, How to improve die alignment
3. Setting Progressive Dies Quickly and Safely - Feeding, Starting strips, Camber compensation, Die protection
4. Clamping Methods - Using threaded fasteners, Sample designs
5. Advanced Diesetting Method - Reducing process variability, scrap and part removal, die cushions, using high-pressure nitrogen systems
6. Relationship of Quick Die Change to EOQ and JIT - Calculating EOQ (economic order quantities), EOQ analysis
7. A Strategy to Institute Quick Die Change - An action plan for traditional shops, applying SPC data
8. Grouping Presses and Dies for Quick Die Change - Common press factors, data analysis
9. Using Spreadsheets to Study Engineering Costs - Maximizing cost effectiveness, maintenance software selection
10. Equipping Presses for Quick Die Change - Types of die-change systems, applications
11. Operating Dies at a Common Shut Height - Avoiding damage during setup, how a press develops tonnage, common die shut height adjustment procedures
12. Employee Acceptance and Involvement - Training logistics and strategies, damage avoidance instruction, union involvement, employee suggestion systems
13. Support Required for Quick Die Change Teams - Responsibilities of manufacturing engineering, production, material handling, production scheduling, and quality control
14. Converting Internal Die Set to External Die Set - Analyzing hit-to-hit times, planning strategies for future improvements
15. Process Variability Reduction - Determining press conditions, press bed leveling, springback compensation
16. Maintenance Requirements for Quick Die Change - Planning die maintenance, computerized die maintenance, system examples, comparing manual and computerized maintenance systems, preventive
17. Safety and Ergonomics - Counterbalance air adjustments, safety guards, pressroom ergonomic factors
18. Case Study: Quick Die Change at Lightolier - Standardization methods, press equipment and die changing methods, installation
19. Design the System to Match your Needs - Meeting the challenge of inventory reduction, basic system requirements, die handling and storage, analyzing project costs, training requirements
20. Case Study: Quick Die Change at General Motors B-O-C Lansing Fabrication - How factors for improvement were identified, continuous improvement techniques, hardware and human resource solutions
21. Automatic Die Change at Mazda - Facility layout, PLC networks, automated blank storage and transportation, part turnover, data file parameters, external pre-staging, employee training and integration
22. Retrofitting Existing Presses and Systems - Analysis of common job shop problems, examples of needed changes
23. Employee Acceptance at Ford Motor Company - Three steps to progress at Maumee stamping, keys to success
24. Steps Leading to Automated Quick Die Change - Available technology, appropriate starting places for automating most job shops
25. Cost-Effective Quick Die Change at Webster Manufacturing Company -Establishing benchmarks, selecting the QDC team, videotaping and analyzing current methods, defining new methods, standardizing manual clamping devices, designing standard tool boxes
26. Electronic Sensors and Controllers - Sensor requirements, standardized approaches, using quick disconnect connectors, sensors in advanced diesetting systems
27. Selecting Maintenance Software - Defining requirements, supplier evaluation, training and implementation, report and screen features of good interactive systems
28. Instituting a Tonnage Meter Program - Operating principles, tonnage meter features, diesetting applications, maintaining databases, waveform signature analysis, tonnage curve analysis
29. Control the Process with Waveform Signature Analysis - Mathematical analysis of the amount of energy stored, chart recorder selection, determining sensor mount locations, snap-through reduction example, quality improvement, press damage reduction
By D.
Smith
432 pages, hardcover, ©2005, $60.00
(quantity and member discounts may apply) Published by
Society of Manufacturing Engineers, Dearborn, Michigan
ISBN 978-0872637135
Available from major
booksellers and SME
Check Search Engines such as Google for
prices and other sources
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