Harnessing Digital Technologies to Enhance Machine Utilization in Stamping Die Shop

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Harnessing Digital Technologies
to Enhance Machine Utilization
in Stamping Die Shop

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Digital is Default
Digital manufacturing (DM) is no longer a fad. At the production level, it can determine:
Quality
Efficiency
Time to
Market

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Embrace a Connected Ecosystem
Using a digital thread, operators can interconnect tools and machinery across the factory floor to:
Gain unprecedented
visibility across a
product’s lifecycle –
from design to use Access large data volumes
gathered from the assembly
line to store shelves and
beyond

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Virtualize the Factory Floor
From the onset, operators can simulate, optimize, and
test processes and products to reduce:
Setup time Manufacturing
costs
Asset utilization

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Identify Factors Hindering Industry-Wide Adoption
Short term cost
prohibitive
implementation
Pressure on
CAPEX for
upgrading legacy
environments
Reluctance to
collaborate with
technology partners
Lack of customized
solutions

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Assess 2017 – 2018 DM Impact
Investments
are
projected to
go up by
of these
initiatives can’t
scale without a
strategic
architecture
of leading discrete
manufacturers plan to
implement product-
as-a-service models
50%
40%
60%

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Adopt An Industry 4.0 Approach
Beyond enhancing resource planning, operators must digitize stamping die shop operations to:
Minimize
production
cycle time
Centralize
equipment
monitoring
Track
machine
downtime
Identify
causes of
failure
Drive efficiencies
and improve ROI
!
!

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Align Tools with Business Goals
A seamless transition to digitally-enabled processes will require:
3D Scanners
Comparing
scanned CAD
model with the
master CAD to
note variations
Condition-Based
Monitoring
Diagnosing
machine health
in real-time
Die Protection
Sensors
Leveraging pressure,
laser, and proximity
sensors to identify die
impurities and
misaligned work
pieces
RFID
Capturing die
information,
monitoring machine
health, sending alerts

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Implement a Connected Architecture
MES
ERP Suit
RFID Database
Machine PLC
RFID Reader
Digital Poka
Yoke
Die
Metrology
Data
Custom Die
Maintenance Program
Edge Computing
OPC Server
Press Condition
Monitoring
• Number of Strokes
• Batch Start/End
• Setup Change
Press Machine Die Tool Room
Tools Room
HMI/VWI
3D

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Reap Long-Term Benefits
Real-time life of die projection01
Detailed failure analysis reports02
Alerts and warnings before die loading03
Linked production schedule to die condition04
Increased control over bought outs and inventory
spares
05
Comprehensive digital die information records06

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Harnessing Digital Technologies to Enhance
Machine Utilization in Stamping Die Shop
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