Staging Process - Some confusion about what this stage actually is

[Manix]

Hi All,

We are manufacturing metal parts that are initially stamped from sheet metal. I am constructing the process flow and one of my collegues had mentioned a 'staging process' that occurs. Now I am remote to the manufacturing site and there seems to be some confusion about what this stage actually is?

Can anyone shed any light?

The material runs off of a roll down the material feeder and it moves over a 'staging table'. Is this simply the stage that feeds it into the stamping machine?

Any ideas or help would be much appreciated.

Thanks,

 

[Jim Wynne]

Hi All,

We are manufacturing metal parts that are initially stamped from sheet metal. I am constructing the process flow and one of my collegues had mentioned a 'staging process' that occurs. Now I am remote to the manufacturing site and there seems to be some confusion about what this stage actually is?

Can anyone shed any light?

The material runs off of a roll down the material feeder and it moves over a 'staging table'. Is this simply the stage that feeds it into the stamping machine?

Any ideas or help would be much appreciated.

Thanks,

Just out of curiousity, why would someone who is not familiar with the process be documenting the process flow? It's hard to tell what's being staged, but it's most likely coils of metal being staged for loading into a coil feeder. The actual loading of the coils into the feeder might be either an automated or manual process.

 

[jmp4429]

I'm thinking what your friend is calling a 'staging process' is where the material coming off the roll is flattened/straightened before entering the stamping die. I could be way wrong though.

 

[Manix]

Hi JSW,

Thanks for your input. I often get asked about being remote from the process and fully understand this is not ideal. Unfortunately the way of the commercial world these days does not favour local production (i.e in the West) and although labour is cheap, so is the quality of information.

We work remotely because we have to, and we don't actually do a bad job. Plus if needs must then there are opportunities to visit the plant anyway.

Thanks again for your input.

 

[Jim Wynne]

Hi JSW,

Thanks for your input. I often get asked about being remote from the process and fully understand this is not ideal. Unfortunately the way of the commercial world these days does not favour local production (i.e in the West) and although labour is cheap, so is the quality of information.

We work remotely because we have to, and we don't actually do a bad job. Plus if needs must then there are opportunities to visit the plant anyway.

Thanks again for your input.

I didn't mean it as a criticism, exactly. One of the basic rules of process flow documentation is being close to the process, though, or at least close to someone who is. I just thought it odd that you would post the question here rather than asking someone at the source.

 

[Manix]

I didn't mean it as a criticism, exactly. One of the basic rules of process flow docuementation is being close to the process, though, or at least close to someone who is. I just thought it odd that you would post the question here rather than asking someone at the source.

No worries, I know it's all a little odd, but again, they would be in bed fast asleep now, and I wanted an idea as soon as possible. Plus it is a highly complex supply chain that starts of one side of the world and quite literally finishes the other!

 

[David Hartman]

No worries, I know it's all a little odd, but again, they would be in bed fast asleep now, and I wanted an idea as soon as possible. Plus it is a highly complex supply chain that starts of one side of the world and quite literally finishes the other!

Manix,

Does the facility in question have email capability? If so, ask for a detailed discription of the staging process via email, and it should be waiting for you when your ready. If not, there's always the possibility of losing some sleep and giving them a call to gather the details, or hopping a flight and viewing the process personally.

Several possibilities for gathering the info needed come to mind, but all involve communication with the people who are running the process.

 

[Manix]

Several possibilities for gathering the info needed come to mind, but all involve communication with the people who are running the process.

Thanks, I have all the bases covered, I do however like to draw on other peoples experience and expertise. Jumping on a plane is not an option at the moment so I think I will give that one a miss.

I will re-confirm everything as I review the process, all questions are fired off to the relevant people and sure enough the information filters through eventually.

Although the communications lines are very much open nowadays, there is still a high amount of information lost in translation.

 

[Craig H.]

Thanks, I have all the bases covered, I do however like to draw on other peoples experience and expertise. Jumping on a plane is not an option at the moment so I think I will give that one a miss.

I will re-confirm everything as I review the process, all questions are fired off to the relevant people and sure enough the information filters through eventually.

Although the communications lines are very much open nowadays, there is still a high amount of information lost in translation.

Why not see if they can send a digital picture along with the description? It might help fill in the details.

 

[Randy Stewart]

Okay, just a couple thoughts here or my 2 cents.

Remember, a process takes an input and changes it somehow. It doesn't matter what or how something needs to happen to the input. Now, if the staging is the same as what I used at a previous job then the sheet metal is orientated to be fed into the press, straightened or at least held with pressure between two rollers, and the feed into the press is controlled. If this is correct it should be in your process flow.
If the feed rate is off the part count may be off or you have double stamps, etc. If the metal isn't fed properly parts can be unfinished, bottom out marker missed, etc. This step can be a biggy, for a properly formed stamping, the bigger the stamping (car roof, hood, deck lid, etc.) or the more intricate the die (fenders, door skins, etc.) the more valuable the feed.
Hope this helps.