Die (Press Tool) Manufacturing Process Key Indicators (KPI)

[psavijay]

The Place where I am working is engaged in Press Tools manufacturing , we are using the following indicators- Tool Mfg cycle time, Right first time trend as key indicator for the process, still we are in search of process specific key indicator for the same.

Any help from forum heavy weights?

[Jim Wynne]

Originally Posted by psavijay

The Place where I am working is engaged in Press Tools manufacturing , we are using the following indicators- Tool Mfg cycle time, Right first time trend as key indicator for the process, still we are in search of process specific key indicator for the same.

Any help from forum heavy weights?

I qualify to answer in terms of girth and mass , so,
I''m not exactly sure what your question is, but it appears that you're making stamping dies (?) and one key indicator for the process is how often the first iteration is successful, and you want to know what a reasonable target or goal might be. If that's the case, here are some questions you need to answer before you can set a goal:

• How good are you now? (Do you have data?)
• What attributes of the present process prevent you from being better?
• Are there any patterns or trends in the existing performance data (e.g., do the same types of errors cause rework and delay)?
• Are there "outside" causes (such as ambiguous customer drawings and specifications) that contribute to rework and delay?

These are just a few, but you get the idea. Before you can set a realistic goal, you have know your process. Just because company X has a first-run success rate of Y doesn't mean that you should set Y as goal arbitrarily--that's a sure recipe for failure, fear and loathing. If someone else is better at what you do than you are, it means that someone else spent more time and effort in designing the process for success.

[Randy Stewart]

Rework costs are a good indicator of process performance. Look at your set up costs and time - how long after the die is loaded do you have a part that meets dimensional requirements. Another area you could look at is the Mean time Between Failures (MTBF) and the Mean Time To Repair (MTTR).

[psavijay]

Hi
I am not interested in targets or Goals, I am interested in Knowing the Indicators used to gage the Die Manufacturing Process?

Some more Elaboration

The Tools are Meant for Reed Valves Manufacturing (Reeds-Part (Port) of Valve assy in Brake compressors)

Tool functionality reqirement is 60 SPM Approx

The Punches are made of Vanadise Material

Per set up Output Requirement is 20,000 strokes

Current year Tool Manufacturing Cycle time Target is 35 Days

Tool Experts are working on a method called Quick Tooling To achieve 20 Days for Tool Manufacturing Cycle time

Seperate Die maintenance Process also in Place

Major Die Failure mode Presence of Notch in the components

Non productive Dev Tool Trial Setup Monitoring also in Place

How good are We? so much data availability-Confusion!

What attributes of the present process prevent you from being better? If we start manufacturing in 1 Day, then the boss will ask the same in Half day-More dangerous!

Still Management is not satisfied with Indicators always denoting Good sign

A.Vijayakumar

[Randy Stewart]

Then what I would suggest is to compare similar die manufacturing time. Punch, hem, cam, etc. compared within type or within size.

Tool functionality reqirement is 60 SPM Approx

The Punches are made of Vanadise Material

Per set up Output Requirement is 20,000 strokes

Current year Tool Manufacturing Cycle time Target is 35 Days

Are you meeting these targets and requirements? Is the Vanadise punches meeting expectations? What is the change over for a dull, broken, or chipped punch?

Tool Experts are working on a method called Quick Tooling To achieve 20 Days for Tool Manufacturing Cycle time

Off the shelf build/development programs have been recycled under many names.

[nirmalan_g]

HI
I am looking for some basic information on press tool design, i.e
Formula for finding dieplate thickness.
Web site in which i can find the information in detail

Originally Posted by JSW05

I qualify to answer in terms of girth and mass , so,
I''m not exactly sure what your question is, but it appears that you're making stamping dies (?) and one key indicator for the process is how often the first iteration is successful, and you want to know what a reasonable target or goal might be. If that's the case, here are some questions you need to answer before you can set a goal:

• How good are you now? (Do you have data?)
• What attributes of the present process prevent you from being better?
• Are there any patterns or trends in the existing performance data (e.g., do the same types of errors cause rework and delay)?
• Are there "outside" causes (such as ambiguous customer drawings and specifications) that contribute to rework and delay?

These are just a few, but you get the idea. Before you can set a realistic goal, you have know your process. Just because company X has a first-run success rate of Y doesn't mean that you should set Y as goal arbitrarily--that's a sure recipe for failure, fear and loathing. If someone else is better at what you do than you are, it means that someone else spent more time and effort in designing the process for success.