February 2021 Volume 3

AUTOMATION

Conclusion Developing and launching a successful automation project requires comprehensive pre-planning analysis led by a competent program manager supported by a cross-functional team of subject matter experts. The team will form a foundation of information necessary to write explicit scopes of work that clearly express the organization’s expectations relevant to the automation project, including but not limited to project timing comprised of runoff and delivery, training requirements, equipment layout, part geometry, etc. Finally, improve throughput by focusing on processes and procedures aimed at reducing downtime events. Implement preventativemaintenance and quick die change strategies to leverage uptime efficiency. ■

process demonstrating an increased production rate. All other conditions remaining the same, a focus to improve die life will allow automated processes to perform at extended periods before tooling repairs are necessary, thus improving OEE. Implementing continuous improvement projects focused on optimizing materials or coatings are constructive in minimizing downtime events. At some point, changeovers, worn or broken tooling will need attention. Reducing the amount of press downtime associated with tooling repair or changeover is fundamental. Single-Minute Exchange of Dies (SMED) is the lean principle that focuses on reducing the time it takes to complete equipment changeovers. SMED theory concentrates on converting internal processes (work performed at equipment, preventing production activity) to external processes (work that can be performed while equipment is operational). Quick die change apparatus and development of methods to address tooling related downtime events prove valuable to facilitate faster tool exchanges, thus reducing downtime on automated and manual processes. Hydraulic or mechanical clamping of individual tools or entire die sets can essentially eliminate the need for manually manipulating fasteners. Incorporating die trolleys, shuttles, and/or power arms further proves beneficial at assisting die maintenance personnel to quickly remove tooling from the forging equipment. Once a successful die exchange is complete and the press is back to producing product, attention can be focused on making repairs to the suspect tooling.

Terry Chilson is a forging professional with 35+ years of industry experience. Throughout his career, Terry held Engineering and Manufacturing management positions at American Axle & Manufacturing and Hendrickson Commercial Trailer Division. In those positions, he was responsible for leading several major capital equipment projects, many with an automation element. Email: erchili@comcast.net

FIA MAGAZINE | FEBRUARY 2021 44