Page 41 - MetalForming September 2017

practices for offline program- ming while working
with operators on the
bend sequence. This collaboration can cre-
ate visuals, such as setup sheets that trav- el with the production order, or graphic dis- plays on the press- brake control to help reduce scrap and deliver setup efficien- cies on the floor.
Meanwhile, operators can
analyze part flow and identify commonalities in a series of part runs, which result in fewer setups and greater productivity. Creating, sharing and stor- ing programs for established best prac- tices can help create fewer challenges with welding and assembly, adding even greater efficiencies to the entire production process.
3) Organize Tools and the Workplace
Organizing tools and tool storage can generate significant waste-reduc- tion results. For example, a proactive step for achieving leaner practices is the implementation of a process to replace worn, damaged or missing tools. Another involves addressing how operators and tools move around the shop floor in order organize the work- place to achieve more efficient press- brake-operations. When operators have to walk several steps to look for and grab the right tools, and then have to walk back to the brake to perform a setup, time and labor are wasted and production costs increase.
A simple solution: Place cabinets with the right tools near the correspon- ding press brake. Placing tool storage near the brakes decreases setup times. It also lessens worker frustration and fatigue. The same is true of clearly iden- tified tools. Identify tools using color coding by machine or cell with paint and laser-marking tools for details such as material number, radius or V-die opening, length, and tonnage capacity. When identifying tools, label the out-
sides and insides of cabinets or tool racks.
Finally, companies should look for changes that can improve operator ergonomics, such as building work-
Clamping systems are designed to reduce manual setup time on
the press brake.
tables and part-support tables at the same height as the point of operation, and using a laser line for operators to better identify bend lines. These simple, low- cost solutions can significantly affect lean practices at the brake while increasing operator
safety and comfort.
4) Create Shadow
Boards
Shadow boards include the shapes and outlines of each particular tool used on the brake. It’s important to ensure that all the tools required for a particular press-brake area are included on the shadow board and are placed in a convenient location for operator use. Doing so will eliminate the time required to find the tools that
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21st Century Chemistry in Metal Working Fluids
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MetalForming/September 2017 39