May 2025 Volume 7

MAINTENANCE

until the needle on the bottom indicator stops. Record the reading on the connection to ram indicator. You may want to measure both the right and left sides. Record readings. 9. Next, we will measure from the connection to the crankshaft. Locate the indicator between the crankshaft throw and the connection rod. Repeat the jacking and measuring process. Now record the readings. 10. Finally, the last measurement is from the crankshaft to the frame of the press. It is best if taken on the RH and LH sides. Locate the indicators from the crankshaft to the frame and perform the same lifting and measuring processes. Record the findings. Now that you have the information, we can analyze it. Working with a qualified rebuilding company, obtain a quotation to properly repair and rebuild your press. In addition, the lubrication system should be upgraded or replaced. The lubrication system is critical to preserving the life of your press. In reality, the cost of a new lubrication system is not as significant as compared to the cost of rebuilding. Now that you understand what you have and the condition of the press as well as the costs involved, we will need to look at the press and work cell as they relate to the OEE-Overall Equipment Effectiveness. Important point: Every piece of the production equipment in the work cell is necessary to maintain OEE. Three items need to be examined, availability, performance, and quality. Below are simple formulas that will assist in obtaining this 8 Hour Shift x 60 Minutes = 480 Minutes Changeovers/Tool Changes = 40 Minutes Breakdown/Unscheduled Downtime = 20 Minutes Solution: (480 – 40 – 20) = 440 divided by 480 = 440 x 100 = 88% Performance Available Time = 420 Minutes Production Rate = 2 Parts/Minute Total Parts Produced = 800 Solution: 800 divided by (420 x 2) x100 = 95% Quality information. Availability

If you purchase a new press, can you gain the 20% that is being lost now? If you rebuild your existing press, can you gain the 20% that is being lost now? The chances of achieving 100% throughput at maximum production levels over time is not great, but you can improve. If you could get a 10% increase in quality throughput what would that do to your profit level. The next thing to consider is the total cost of the repair/rebuild and the total cost of machine replacement including removal of the old machine, foundation changes/requirements. • How long will it take to pay for the new machine? • How long will it take to pay for the rebuild? • What is the expected life of the new machine and the rebuilt machine? Another important consideration relates to the tooling/die condition. Are the problems with the production/quality due to the press, tooling or both? Here is an advantage of using a four channel tonnage monitoring system. Seeing what is actually happening in the die space during production regarding loading characteristics can also assist in determining the condition of the press and tooling. Another consideration is the flange thickness as it should be. Excessive flange thickness can also show that there may be an issue with the press or tooling. Perhaps the most important point for determining which path to choose; replacement or rebuilding, is an in depth understanding of your existing process and equipment vs what you might be able to obtain by replacing your existing equipment. The key to this information is inspection, monitoring, benchmarking and analyzing your processes. Inspections are not just a maintenance tool. Inspections and monitoring give information to make the best decisions we can make for a safe and prosperous future. Jeff Fredline Owner-Industry Consultant Prestrade Phone: 615-517-4282 Email: fredline.jeff@gmail.com

Good Quality Parts = 750 Defective Quality Parts = 30 Set Up Scrap Parts = 20

Solution: 750 divided by (750 + 30 + 20) x 100 = 94% OEE Calculations (Overall Equipment Effectiveness) Availability x Performance x Quality + OEE 88% x 95% x 94% = .78584% or 79% Based on the above information, can you justify the purchase of a new press or rebuilding your existing machine?

FIA MAGAZINE | MAY 2025 21