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Managing the Speed of Change

February 10, 2025
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Automotive-metal-stamping technology continues to advance and mature—as it always has—but today this happens more rapidly than ever, and with profoundly more complex technologies. Employer training programs must keep pace with this speed of change to avoid a skills gap and skills shortage.

Nucor-steel-sheet-metal-coilWhen existing workforces’ skill sets do not match the capabilities required to execute their jobs, a gap occurs. When employers cannot fill openings in technical occupations, a skills shortage exists. Factors responsible for skills gaps and shortages include a lack of investment in technical training and skills development, rapid market changes combined with low overall unemployment, and weaknesses in available technical-training programs.

Rapid Changes Affect Automotive-Stamping Technology

The past 30 yr. have led to an ever-expanding class of high-tensile-strength materials called advanced high-strength steel (AHSS). Unlike the boron-based hot-forming grades, these materials are designed to be cold-formed in traditional stamping dies and press lines at room temperature.

During the last decade, a third generation of AHSS materials has emerged, providing tensile strengths approaching that of hot-formed stampings but with enough ductility to be cold-formed. These ultra-high-tensile-strength materials can push press lines beyond their designed-for capacities.

Beyond steel, other materials change the way that stamping companies operate. For example, aluminum stamping can be challenging, especially when working with new or unfamiliar alloys.

The digital world works hard to keep pace with new automotive materials and stamping technology by delivering more accurate formability analysis, improving springback prediction and responding to variations in the stamping process. Another recent advancement: simulating programmable servo press slide motions in combination with programmable servo transfer systems to optimize strokes/min.

Disruptions Drive Changes in Behavior

We all must confront unexpected changes throughout life. How we perceive disruptions often determines our response. If viewed as a threat, we may react defensively to a change and take immediate action to protect ourselves, our perceptions or our comfort zones. However, perceiving change as an opportunity can lead to a more thoughtful and reasoned response—delaying action or continuing in our established routines as we wait to see how the situation plays out. 

When companies face major disruptions, how their managers perceive disruption influences how they describe it to the rest of the organization, and that can determine the organization’s response. If the organization sees the disruption as a threat, it may overreact by committing too many resources too quickly. But if seen as an opportunity, insufficient resources may be allocated to a disruption’s progress, especially should business-as-usual be the desired outcome. Management’s attitude toward disruptions also will determine how employees perceive and accept them. 

Examining the automotive industry, our perception continues to evolve, in both the energy sources that vehicles use and the way that we view transportation. Autonomous vehicles will challenge the necessity of owning a personal car, and we must adapt to the fact that many vehicles no longer will have drivers behind the wheel. 

Disruptive technologies in metal-stamping plants impact business operations in similar ways. For example, consider the use of radio frequency identification (RFID) and Bluetooth communication for die tracking, including dunnage-rack and material-retrieval-cart tracking via high-frequency and ultra-high-frequency communication. Other examples: industrially robust RFID systems for die shut-height validation, mechatronic systems for monitoring die processes, and value-added in-die validation and error-proofing. One more: quick-die-change technologies using remote energizing and information transfer via wireless couplers on transfer dies and progressive dies.

Real-time, nondestructive production-monitoring tools have wide use for various manufacturing areas including joining and fabrication. And, we now see applications of real-time and nondestructive evaluation tools to monitor and assess incoming coil properties, blank-surface finish, lubrication-film thickness, die stresses, part temperature and final-stamping quality such as springback and geometry tolerances.

Employees receiving advanced training from their employers become better equipped to do their jobs and will, in turn, contribute more significantly to the company’s success. Properly trained employees also are more fulfilled in their careers. Upskilling a current employee with whom organizations have spent time building a positive relationship can be more cost-effective than hiring new employees. Of course, corporate training requires significant time and financial commitments, but it’s also an investment in a company’s most important asset, its employees. 

Continued advancements in manufacturing technology require a well-educated and highly trained workforce ready for the challenges. Considering the speed of change in automotive manufacturing, this will be the difference between organizations that are prepared and those that falter.  MF

Industry-Related Terms: Alloys, Die, Ductility, Lines, Thickness, Transfer
View Glossary of Metalforming Terms

 

See also: Nucor Corp.

Technologies: Materials

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