Tuesday, September 12

7:30-9:30 a.m.

Women of FABTECH

How Did I Get Here? My Pathway to Manufacturing

Moderator—Teresa Beach-Shelow, Owner, Superior Joining Technologies

Amanda Reel, Training Engineer, Trumpf Inc.

Mahrya Osheaski, Vice President of Sales, IFS Coatings

Karen Gilgenbach, Vice President—North Zone, Matheson Gas

Lisa Habe, President and Chairman of the Board, Interlake Stamping of Ohio

8:30-9:30 a.m.

Keynote: “Nasty Bit of Rough”

Sports speaker David Feherty discusses life as a golfer and commentator, using humor to discuss some of the more comical moments from life off tour.

12:30-1:30 p.m.

Leadership Exchange: Building the Future Workforce

Moderator: Jeannine Kunz, Chief Workforce Development Officer, SME

Connie King, Director Workforce Development, PMA

Edward C. Dernulc, Director-Foundation, FMA

Monica Pfarr, Executive Director, AWS Foundation

Lara Threet, Mississippi State University

Wednesday, September 13

8:30-9:30 a.m.

Keynote: Digital Leadership: The 5 Simple Habits of Digital Leaders

Erik Qualman, author/motivational speaker

12:30-1:30 p.m.

Leadership Exchange: Advancing Robotics “Rocking” the Fabrication Metal Industry

Moderator: Aaron Prather, Director, Robotics & Autonomous Systems, ASTM Intl.

Edward Mehr, Co-Founder and CEO, Machina Labs

Gijs Van Der Velden, CEO, MX3D

Arnold Kravitz, CTO, Blueforge Alliance

Chuck Brandt, CTO, ARM

Thursday, September 14

8:30-9:30 a.m.

Panel Discussion: State of Manufacturing

Moderator: Joanne Moretti, Chief Revenue Officer, Fictiv

Panelists: Sabrina Paseman, General Partner, Omni Venture Labs

Jean Olivieri, COO, Fictiv

Scot Lindemann, CEO, Mission Design & Automation

10-11 a.m.

Leadership Exchange: Financial Insights to Grow Your Business

Moderator: Micki Vandeloo, President, Lakeview Consulting, Inc.

John Madsen, VP, Blackline Group

Mike Devereux, CPA, CMP, Wipfli

FABTECH 2023 Stamping Sessions­—Chicago, IL

Monday, September 11

10-11:30 a.m.

Session S11: Sensors for Die Protection—Make Die Crashes a Thing of the Past

Jim Finnerty, Product Manager, Wintriss Controls Group LLC

Die-protection systems have been around for decades. Recent advances have made these important monitoring devices more powerful and more forgiving. Attendees will learn how to get the most out of a die-protection system. This presentation will detail the proper use of control functions and features, and identifies the three most important factors to consider when selecting a system.

Participants also will learn how to select and properly apply the right sensor for any application. This presentation details the advantages and limitations of each sensor type, and provides tricks and tips for sensor selection, installation, wiring and maintenance.

Session S21: Maximizing Progressive Die Performance During Production

Peter Ulintz, Technical Director, Precision Metalforming Association

Many progressive die processes do not run at optimum production speeds. Many factors influence progressive die performance including die setup procedures, improper feed settings, improper straightener settings, dynamic shut-height variances and press condition. This presentation examines the major factors influencing progressive die performance and part quality, including a focus on feed angles and proper pilot-release timing (including lag-time compensation).

Noon–1:30 p.m.

Session S11: Automatic In-Die Part Quality Monitoring & Tool Adjustments

James Barrett, MSEE, President, Link Electric & Safety Control

Implementation of part measurement, die adjustment and part tracking can result not only in 100-percent verification of critical part features, but also in significantly increased machine utilization, accurate production and scrap rates, and more reliable die protection. Learn the practical methods to select, apply and integrate sensors and control systems in order to fulfill accuracy and quality requirements.

Session S22: Methods and Tips for Solving Progressive Die Problems

Peter Ulintz, Technical Director, Precision Metalforming Association

Progressive dies are routinely reworked, modified or adjusted in the press when production problems occur or quality issues arise. In many instances, the die is not the root cause of the problem and, therefore, the problem resurfaces or new problems are created. This presentation examines key elements for solving progressive die problems, provides tips for success and offers validating solutions.

2–3:30 p.m.

Session S13: Estimating Metal Stamping Dies

Jeff Bennett, President, Tool Planners

This presentation will explore the procedures and technologies required to successfully plan and price metal stamping dies. Emphasis will be placed on attendees improving accuracy, saving time and lowering costs related to die quoting. This presentation will walk through a sample estimate including quote request, part data, feasibility, die construction and cost-estimating methods. Highlights include die-quoting metrics and ideas for continuous improvement.

Session S23: Alternative Stamping Methods

Servo-Hydraulic Press Not Only Saves Energy

Stefan Hildebrandt, Head of Sales, Maschinenfabrik Lauffer

Reduced energy requirements, high reproducibility and cost-effectiveness were the main development goals of the new Lauffer S-Line hydraulic press series. These requirements are implemented with a new modular drive concept, which simply consists of a robust variable displacement pump with variable-speed servo motor. By dispensing with conventional proportional valve technology, this leads to a significant increase in energy efficiency with simultaneous positive effects in the controllability of the individual axes. In particular, sophisticated deep-drawing processes benefit from the advantages of the new technology. They also can be programmed intuitively and easily using the new HMI generation. This presentation will explain with three simple steps how to find the right drive concept for the customer’s application and show useful options helping to increase production efficiency.

Robotic Sheet Shaping: A Thesis on the Future of Manufacturing

Edward Mehr, BS, Computer Science and Business Administration, Machina Labs

One of manufacturing’s dirty little secrets is that virtually all production lines are purpose-built to produce just one component or product, which means that any design change renders that production line obsolete and requires returning to square one. While those lines are operational, uptime pressure is such that manufacturers are loath to apply patches to known security vulnerabilities because they require downtime that leads to lost revenue and unhappy customers.

Tuesday, September 12

10-11:30 a.m.

Session S15: Processing Parts for Progressive Dies Part –1—Engineering Principles and Design Guidelines

Peter Ulintz, Technical Director, Precision Metalforming Association

Progressive stamping dies are exposed to large internal and external forces, shocks, and vibrations that must be mitigated during the die design process. This presentation addresses key engineering principles and design guidelines that should be considered during every die design. Topics include off-center loading, horizontal die forces, snapthrough loads, the effects of reverse tonnage, material hold-down and stripping systems, stock guiding and lifting systems, and designing dies with maintenance in mind.

Session S25: Maximize your Lubricant Performance—Safety and Reuse

Bob Anderson, Technical Services Manager, Tower Metalworking Fluids

Learn methods to evaluate the performance of your metalworking process lubricants and their safe usage. What do all of those pictures on my drums mean? Are they safe? I’m using way too much fluid, and it costs too much; what should I do? We’ll discuss these topics and more. Participation is encouraged; please bring your questions.

Noon-1:30 p.m.

Session S16: Processing Parts for Progressive Dies Part 2—Evaluating Strip Layouts

Peter Ulintz, Technical Director, Precision Metalforming Association

Several different progressive die strip layouts can be derived for any given part. But how does one know which process is the best? This presentation proposes a strip evaluation and ranking method for progressive die strips and various part-carrier designs.

Session S26: Lightweight Sheet Metal for the Automotive Industry

Kidambi S. Kannan, Technical Specialist, AutoForm Engineering USA, Inc.

Lightweighting in automotive applications provides for reduced carbon emissions, increased occupant safety and improved vehicle performance. In this presentation, learn the history and current usage status of sheet metal aluminum grades and quenchable steels. The presentation also provides an overview of technologies for the production of sheet metal components: cold, warm and hot forming of aluminum; and press hardening of quenchable steels. And, learn digital-engineering best practices for the engineering, simulation and validation of the above production processes.

2–3:30 p.m.

Session S17: Building a World-Class Tooling Information System

Jeff Bennett, President, Tool Planners, Inc.

The presentation explores the benefits of managing special tooling assets located internally and at supplier locations. Dies, molds, fixtures, gauges and automation-system capability affect part quality, material usage, labor cost and sourcing decisions. Attendees will learn how to use web-based technologies to quickly and efficiently document, manage and maintain special tooling to lower supply-chain risk and improve performance.

Session S27: Smart Production and Smart Engineering—A Winning Combination

Gianfranco Ruggiero, Senior Product Manager, AutoForm Group

Andreas Gebele, Product Manager Digital Solutions, Schuler Pressen GmbH

“Smart Production” often is understood as a strategy that involves tracking relevant data from a running production process, using artificial intelligence algorithms to determine optimal process windows and deriving control strategies to make sure that production operations remain inside the “zero failure” process domain.

Before production can start, however, stamping processes are designed, engineered and digitally validated by process engineers investing their expertise and knowhow. So, when production starts, a vast amount of relevant engineering knowhow and data already has been generated, which can be leveraged to accelerate production rampup and to strive for zero-failure production. This is what is called “Smart Engineering.”

This presentation explores how smart production and smart engineering can support each other, by combining the smart engineering approach with real-life press-shop production-monitoring data in order to optimize press shop production operations.

Wednesday, September 13

8–9:30 a.m.

Session S28: Creating Operational Excellence in the Press Shop

Will Healy III, Global Segment Manager, Universal Robots

Part-quality issues and missed production quotas can sink profitability in a competitive marketplace. The same problems reappear but due to stress, lack of training or hard delivery deadlines we struggle to find the time to solve the root cause of the problem. The challenge of workforce retirement drives us to understand how to integrate new generations into the press shop and successfully drive culture change in the organization. This presentation will discuss how to systematically achieve operational excellence using best practices and technology to improve uptime and eliminate nuisance stops. Drawing on more than a decade of personal experiences, successful philosophies will be offered to overcome challenges in metal stamping production. When operational excellence is achieved, manufacturers find that they have improved their competitive position, are more in touch with their business, have reduced costs and waste, have eliminated die crashes, and are boosting productivity.

10–11:30 a.m. 

Session S19: Metal Stamping Press Maintenance Best Practices

Jeff R. Fredline, President/Sales Engineer, Prestrade

Attendees will learn to identify metal stamping press problems and the steps needed to correct the issues, as well as the conditions that can be avoided by proper maintenance and troubleshooting. Participants also will understand how to optimize their maintenance investments and obtain the best results from their efforts.

Session S29: Intelligent Metalforming

How Smart is Your Press Shop?

Tiago Vasconcellos, Sales Director, Schuler North America

Digitalization makes it possible to optimize for overall equipment effectiveness: increase manufacturing performance, quality and availability.

The Smart Press Shop, a newly formed joint venture between Porsche and Schuler, is an exemplary case study for smart manufacturing standards. Discover innovative and practical ways to incorporate digitalization into production and become a state-of-the-art stamping facility. 

This presentation will address why the Smart Press Shop was created, the technologies included within the Smart Press Shop, the results that Schuler and Porsche are experiencing, what manufacturers should be thinking about when purchasing press systems, and how manufacturers can begin incorporating Smart Press Shop practices.

The Impact of Sheet Metal Types and Procurement Specifications on Die Maintenance and Production Uptime

Peter Ulintz, Technical Director, Precision Metalforming Association

Sheet metal type and ordering specifications can heavily influence the cost of die maintenance and production. This presentation looks at the impact of sheet metal thickness, type and temper (aluminum, copper alloys, mild steel, stainless steel, HSLA and AHSS) on press performance (tonnage, energy, reverse unloading) forming modes (bending, drawing and stretching), die wear and die breakage. Other topics include sheet directionality, proper cutting clearances, deep drawing guidelines, frictional issues and lubrication requirements.

Noon-1:30 p.m.

Session S110: Reducing Die-Repair Costs and Optimizing Die-Maintenance Programs

Peter Ulintz, Technical Director, Precision Metalforming Association

Die maintenance and die repair are not the same thing. Nonetheless, many stamping companies lump together the cost of die maintenance with die repair to simplify reporting. This presentation examines the difference between repair and maintenance and explores the benefits of four primary maintenance programs: reactive, preventive, predictive and proactive. Attendees will learn how to distinguish between the cost of maintenance and the cost of repair, how to measure and report each properly, and make a business case for a robust die-maintenance program that minimizes the cost of die repair.

Session S220: Stamping Optimization

A Holistic View of Press Automation

Marc Decker, Director Sales Northern Europe & USA, Automatic-Systeme Dreher GmbH

In today’s world, it is becoming increasingly important to look at the complete manufacturing process and not just the one, perhaps small, part for which the company is responsible. This can be an automation area of a press line, but also the complete press automation from the starting material through the intermediate stages to the finished component. Today’s challenges, such as batch size 1, cost reduction, and simple and direct implementation, play a major role.

With new technical requirements in automotive and energy industries, the lines also must be able to optimally feed and discharge the new and very sensitive materials to and from the process. This can be best achieved if the press automation solution provider not only knows one part of the automation area but has all automation solutions in its hands, whether for completely new plants and installations or for modernizing existing plants and systems.

Increasing Your Productivity and Profitability with an In-Die Tapping or Insertion System

Vaughn Falkenberry, Project Engineer, and Paul Rader, Project Engineer, Pronic  In-Die Solutions, Inc.

The presentation will cover how in-die tapping and in-die insertion systems eliminate the secondary process of offline tapping and insertion, increasing the productivity and profitability of stamped-metal-part projects. This is achieved by performing the tapping and/or insertion function simultaneously with the stamping function in the press. The various tapping and insertion systems available, and how to determine if an in-die tapping and insertion system is feasible for a project, will be discussed as well.

2-3:30 p.m.

Session S110: Cost-Effective Die Improvements to Ease In-Press Maintenance

Peter Ulintz, Technical Director, Precision Metalforming Association

Designing dies for ease of maintenance is a design objective for most new die builds. However, many dies are built without maintenance in mind. What can be done once these dies are released for production? This presentation provides tips for easing progressive die maintenance. Topics include improvements to cutting and punching operations, minimizing burrs, improving match-cuts, improving shimming procedures, setting proper punch engagement when staggering punches, springback-compensation methods, stripper and pressure pad balancing techniques for feeding new strips, improving coil change procedures, and reducing associated miss-hits. MF

See also: Precision Metalforming Association

Technologies: Management

Subscribe to the Newsletter

Start receiving newsletters.