Page 32 - MetalForming September 2015

Clamps Gain a Grip on
Die-Change Efficiency
With improved die-change ergonomics top of mind, pressroom managers at the new showcase Whirlpool plant embrace hydromechanical clamping nuts to speed changeovers and avoid die damage.
BY BRAD F. KUVIN, EDITOR
Consecutive years (2013-2014) of significant growth in home-appli- ance sales had the Whirlpool Cleveland (TN) premium cooking oper- ations plant pushing hard to keep up with demand. The welcomed flood of work, however, contributed to a perfect storm that kept managers on their toes to stay atop the rising tide of activity.
First, the plant was relatively new and experiencing some growing pains. Christened in 2012, the showcase facil- ity welcomed hundreds of new employ- ees, creating a training challenge. And, thousands of stamping dies were moved in, along with dozens of press- es with varying tonnage capacities.
Moving several production lines across town and adding new processes in the new facility, all while keeping up with consumer demand for the plant’s premium cooking products was a significant task. Achieving the task included much hard work, and the plant was rewarded with steadily improving productivity measures.
Says fabrication manager Jim Stew- art:
“While a lot of our measures have improved significantly this year, we
Sound die-change practice starts with well-organized workstations. To that end, Whirlpool is customizing Creform material-handling carts to organize the new Hilma hydromechanical clamping nuts and accompanying bolts, to provide visual cues to die setters and press operators.
30 MetalForming/September 2015
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recognized several opportunities for even further improvements in a num- ber of areas.”
The Press-Shop Project
January 12, 2015, marks the date
when Stewart and value-stream direc- tor Gene Sparks sponsored the plant’s Press Shop project. The team set out to bring continuous improvement in areas including:
• Error-proofing all die changes;
• Ensuring that safety checklists are