David Alkire Smith

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Quick Die Change
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

1.   Introduction
evolution of QDC, benefits of ODC

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 Methods
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, $89.00 (quantity and member discounts may apply) Published by Society of Manufacturing Engineers, Dearborn, Michigan ISBN 0872637158 Available from major booksellers and:
SME 1-800-733-4763 www.sme.org

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