Page 34 - MetalForming December 2010

George Keremedjiev has been writing this column for more than 20 years. He regularly consults with metalforming companies worldwide and provides metal- formers with training on the appli- cation and implementation of sen- sors for die protection. For more information on his seminars and consultancies, contact:
Tecknow Education Services, Inc. P.O. Box 6448
Bozeman, MT 59771
phone: 406/587-4751
fax: 406/587-9620
www.mfgadvice.com E-mail: gk@mfgadvice.com
Ihave been asked, again and again— especially in this difficult economy— to explain the cost justification and payback for the implementation of a serious sensor program. The following is derived from a handout that I give to metalforming-company executives wishing to better understand how to justify the implementation of electron- ic sensors via a serious program.
based error-proofing permeates the entire plant with consistency.
12) The freeing-up of the toolroom to be more proactive and build error- proofing into the process.
13) Hundreds of thousands of dol- lars in annual cost savings due to the implementation of a serious sensor program in pressrooms and assembly areas.
Some typical questions regarding what it costs not to have the program? • What is your annual cost of die
METALFORMING ELECTRONICS GEORGE KEREMEDJIEV
Cost Justification for a Sensor Program
First, some actual ed by metalformers program:
1) Automatic presses running from 35 to 150 per- cent faster.
2) Multiple auto- matic presses per one operator (from two to six per opera- tor).
3) Minimization of die crashes for all active dies, with some shops having zero die crashes in a given year.
benefits as report- that have such a
A culture of electronic sensor-based error-proofing will permeate the entire plant with consistency.
repair?
• What is the
annual cost of die maintenance?
• What is the cost of quality, sorting and rework?
• What is the cost of press and die downtime?
• What are the speeds of the presses, and convert this to dollars/min.?
This CD-ROM presents dozens of George’s columns as well as papers and exclusive new presentations covering all aspects of die protection and part-quality inspection, starting and maintaining sensor programs, the role of controls in in-die sensing, and the benefits of a sound sensor program. Order it online at www.metalformingmagazine.com.
32 METALFORMING / DECEMBER 2010
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4) Drastic reduction in routine die maintenance (by as much as one third). 6) Elimination of scrap, double hits
and die damage in single-stroke dies. 7) Elimination of part sorting and rework through automated in-die part
measurement.
8) Blending of stamping and assem-
bly into one die (example: in-die weld- ing of hardware).
9) Pressroom efficiencies (actual part run time) of 85 percent plus.
10) Detection of assembly errors at the assembly process, prior to shipping. 11) A culture of electronic sensor-
• How many operators per press in dollars/yr.?
• What is the cost of express ship- ments and overtime labor to make up the schedules?
• What is the cost of nasty surprises such as canceled orders?
Using the above statements and guidelines, it is possible to broaden the understanding of why electronic sen- sors, when properly applied, pay for themselves hundreds of times over. Take a deep breath and then calmly grasp the full extent of the costs of not having a serious die-protection and in-die part quality measuring program. MF