How to Define Scrap Metrics & Objectives - Stamped Cold Rolled Steel Fasteners

J

juliov

#1
Attention Quality Pros:

My company stamps cold rolled steel fasteners to be used in bedding and upholstered furniture and some automotive seating industries, the clips are stamped from slitted strips of steel of about 1/2" to 3/4" in width and about .033 to .039" in thickness, the strips are part of slitted parent coils with about 12 strips per parent coil.

The issue we are having is how to define a metric for scrap, the pressess are small and are very efficient in the stamping, we are not sure as to what to call scrap, for ex: nonconforming material stamped can be classified as scrap, or set up of the presses and the material that is wasted in the set up process? We know the process naturally produces some by product due to the stamping it is not much.

Any ideas as to scrap metrics let me know.
thanks,
 
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Jim Wynne

Leader
Admin
#2
Re: How to Define Scrap Metrics and Objectives - Stamped Cold Rolled Steel Fasteners

Attention Quality Pros:

My company stamps cold rolled steel fasteners to be used in bedding and upholstered furniture and some automotive seating industries, the clips are stamped from slitted strips of steel of about 1/2" to 3/4" in width and about .033 to .039" in thickness, the strips are part of slitted parent coils with about 12 strips per parent coil.

The issue we are having is how to define a metric for scrap, the pressess are small and are very efficient in the stamping, we are not sure as to what to call scrap, for ex: nonconforming material stamped can be classified as scrap, or set up of the presses and the material that is wasted in the set up process? We know the process naturally produces some by product due to the stamping it is not much.

Any ideas as to scrap metrics let me know.
thanks,
First you have to define what "scrap" means. In stamping there's always going to be scrap material left over, which includes all parts of the strip that are left over after the parts have been made. "Scrap" can also refer to "bad" parts that can't be salvaged through rework (for whatever reasons). The idea is to reduce the amount of material that doesn't wind up in the parts themselves to a reasonable minimum. This includes setup scrap--any part of the raw coil that gets thrown out before production actually begins, as well as bad parts produced during the run.

In general, it's best to classify scrap by process, such as setup scrap, production scrap, etc., and then by defect types--mis-hits, excessive burrs, etc., the object being to address the causes and correct them.
 
J

juliov

#3
Re: How to Define Scrap Metrics and Objectives - Stamped Cold Rolled Steel Fasteners

Hello Jim,

Yes, you are on the right track about the defining scrap, we had not seen it as such, it appears as an equation:
scrap = set up scrap + prod scrap + storage scrap + in transit scrap+ etc..
and the defect types can be defining factors to classify the what is scrap?

Ok, thanks for the input, any other ideas or comments let us know.
THANKS,
 
P

Pudge 72

#4
As a Stamper myself - remember, check the quote, usually there are provisions for cost based on your strip layout that take into account the inherent scrap produced by the die.

Differentiate this from the scrap produced from the part.

You can however find out the inherent scrap and change that amount by potential redesign of stations, a program such as Logopress or Quickpress can tell you exactly what % of material you are producing / scrapping in slugs as a result of progressions.

Of course, the scrap produced by the process itself is then measured as the output of product that either conforms or does not - use that data to improve your process.
 
J

juliov

#5
Thanks for the very valuable info Pudge, our mgmt team will integrate your comment during the evaluation of scrap meeting. By the way, how did your operators of the presses collected the scrap? where was it taken to for weighing? etc.
Thanks
 
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