Page 29 - MetalForming June 2013

three in 2014. Of the 15 presses, three are Bruderer high-speed models (rated to 800 strokes/min.) and 12 are 22- to 100-ton gap-frame Minsters rated to 500 strokes/min. Each overhaul project includes replacing aging and outdated press controls with new Wintriss Smart- Pac 2 press-automation controls inte- grated with Wintriss Shadow 8 light curtains, clutch/brake controls, and greatly enhanced die-protection and tonnage-monitoring capabilities. Also included with each setup is Wintriss’ DiPro Sensor Interface, which enables the shop to connect electromechanical and discrete-output electronic sensors to the control. Front-panel connectors allow wiring individual sensors, while larger connectors allow use with die- mounted junction boxes for connec- tion of as many as eight sensors to the DSI with a single cable.
McCullah notes that the plant’s die- protection efforts were championed by a press technician/setup person, “rather than it coming from me. He was trained by Wintriss, then came back and shared the knowledge gained with the rest of our crew. Since then, our main- tenance staff has completed a more advanced class at Wintriss on diagnos- tics and other features of the controls.”
With its new focus on press-line electronics, “any time a job goes into a press, it is not allowed to run until it has sufficient die protection,” insists McCullah. “We have some 300 active dies that make our 800 different part numbers. Although a die may not run for 2 or 3 yr., when it does get scheduled for production we not only make sure it’s sharpened and cleaned, we also ensure the setup includes sensors— either added to the dies when physi- cally possible, or added to the press.”
The plant’s approach to integrating sensors mirrors its press-overhaul approach—everything is standardized to simplify plant-floor decisions and help avoid errors. In the middle of the pressroom sits an 8-ft.-tall shelving unit that serves as the plant’s “sensor toolbox.” On it, press technicians can find stock-feed sensors, ring sensors, proximity sensors and laser sensors.
To upgrade its press lines, ARaymond Tinnerman standardized on Wintriss SmartPac 2 press controls integrated with Wintriss clutch-brake controls, Rapid-Air servo feeds and Wintriss Shadow 8 light curtains. Shown is a Minster 22-ton high-speed gap-frame press with 2-in. stroke and 9-in. shut height.
“We run a lot of progressive dies that make some rather complex forms,” says Stith, “and several styles of fas- teners can prove challenging to release from the dies. Running at speeds of 200 or more strokes/min., we’ve got to ensure that parts leave the dies; stuck parts can quickly pile up and cause a die crash. So, to check for part ejection we now employ ring sensors or laser sensors. Lasers get the call for sensing extremely small fasteners.”
Driving Plant Cadence
With more reliable equipment and controls on board and with sensors now protecting its dies, Stith and McCullah have raised the bar on throughput. And they note that the bar has not stopped rising.
“Having gained control of produc- tion and stabilized our process, we’re now challenging ourselves and pushing our run standards,” says McCullah. “Our goal is to have our plant-floor workers drive plant cadence and push our run standards. If a job is running at 150 strokes/min., for example, we want operators to see if they can get it to run at 200 strokes/min. We have the equipment ready and die protection in place, so let’s stop sitting back and push forward. Last year we experienced a 40-percent gain in throughput from our gap-frame presses, which went from producing 11,000 pieces/hr. to 15,000 pieces/hr. We expect another 10-percent gain in 2013. And output from the three Bruderer presses climbed by 15 percent, to nearly 40,000 parts produced/hr.”
How successful is the plant at realiz- ing the lofty goals set by McCullah and Stith? “We set management business
The ROI Story
ARaymond Tinnerman has invest- ed $50,000 per press line to make the necessary mechanical and con- trol upgrades to bring the lines up to snuff. The return on investment comes quickly and easily when you consider a few key process improve- ments that have been realized:
• Die-Repair Costs—Decreased from $1.13/1000 pieces to $0.65/1000 pieces
• Overtime Hours Worked—Decreased from 5600 hr./yr. to 500 hr./yr.
• Average Run Rates—Increased from 11,000 parts/hr. through the shop to 15,000 parts/hr.
www.metalformingmagazine.com
MetalForming/June 2013 27