Abstract: Manufacturing cost and setup time are the hot topics to improve in Metal Stamping industry because material and components price are always rising up while costumer requires to cut down the component price year by year. The Single Minute Exchange of Die (SMED) is one of many methods to reduce waste in stamping industry. The Japanese Quick Die Change (QDC) dies system is one of SMED systems that could reduce both of setup time and manufacturing cost. However, this system is rarely used in stamping industries. This paper will analyze how deep the QDC dies system could reduce setup time and the manufacturing cost. The research is conducted by direct observation, simulating and comparing of QDC dies system with conventional dies system. In this research, we found that the QDC dies system could save up to 35% of manufacturing cost and reduce 70% of setup times. This simulation proved that the QDC die system is effective for cost reduction but must be applied in several parallel production processes.
Abstract: The purpose of this paper is to simulate the production process of a metal stamping industry and to evaluate the utilization of the production line by using ARENA simulation software. The process time and the standard time for each process of the production line is obtained from data given by the company management. Other data are collected through direct observation of the line. There are three work stations performing ten different types of processes in order to produce a single product type. Arena simulation model is then developed based on the collected data. Verification and validation are done to the Arena model, and finally the result of Arena simulation can be analyzed. It is found that utilization at each workstation will increase if batch size is increased although throughput rate remains/is kept constant. This study is very useful for the company because the company needs to improve the efficiency and utilization of its production lines.
Abstract: Metal stamping die design is a complex, experiencebased
and time-consuming task. Various artificial intelligence (AI)
techniques are being used by worldwide researchers for stamping die
design to reduce complexity, dependence on human expertise and
time taken in design process as well as to improve design efficiency.
In this paper a comprehensive review of applications of AI
techniques in manufacturability evaluation of sheet metal parts, die
design and process planning of metal stamping die is presented.
Further the salient features of major research work published in the
area of metal stamping are presented in tabular form and scope of
future research work is identified.