Stamping Archives

We know stamping from just about every perspective you could imagine. Here are some of our thoughts on what it takes to optimize scheduling in a metal stamping plant using IT.
 


Optimizing a Metal Stamping Facility

This is an oveview of what IT systems are needed to effectively operate a modern stamping plant that supplies parts to customers on a just-in-time basis. We wrote this years ago and have recently updated it for inclusion here.

The audience for this report is controllers, supervisors, plant managers or anyone else who cares about improving the performance of a metal stamping plant.

The objectives of any stamping plant:

Be Lean - The objective is to maintain minimum balances on hand for both stamping and assembly sides

Avoid Quality Problems - Rejected parts internally and externally cause realtime schedule changes

Reduce Unscheduled Downtime - Not running to standard or not running at all is the #1 schedule killer

Build Realistic Cycle Rates - Scheduling must be armed with cycle rates which reflect current reality.

Know Your Hit to Hit Performance - Regardless of our die set performance, we need to be able to predict how long they will take.

Build Realtime Systems - How are we doing right now relative to our current set of ship deadlines?

Production control at stamping plants must fulfill the central requirement of meeting customer requirements by the due date. However, this must be done keeping inventory levels low to operate in the lean manufacturing paradigm.

In attempting to meet these contradicting demands, the stamping plants can incur high premium freight costs. It’s not uncommon for plants to operate in fire-fighting mode, where Distribution takes over the role of Scheduling in order to keep the most needy customers from being shut down.

Read the entire paper (400K PDF)


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More Stamping

We've been involved in all aspects of counting, downtime, monitoring systems for stamping. We know what good looks like. We know the other side too. Here's an overview of a stamping system we knew well many years ago.