Designing of New Chute Plate for Quick Die Change on High Speed Presses

Abstract

Stamping process uses high productive level machines. Machine capacity utilization is a key goal in achieving minimum time consumption for setup change time or idle time. Tool change over process is recognized as possible area for reducing the time consumption. The main objective of the present study is to identify the root causes of bottlenecks operation and implement possible solution to the problems. Single minute exchange of die (SMED) method and quick die change (QDC) technology were applied at major bottleneck setup operation in one of major company in India (Crompton Greaves Ltd.). Chute plate design was found as the major cause for high setup time. A standard chute plates was designed for rotor and stator chute with software solid work 9.0™ and designed some other relevant assembly component required for easy setting of chute. Stress analysis of chute plates was performed by using software ANSYS 11.0 before actual manufacturing of component to ensure design safety. The SMED method has been improved by additional technology QDC and design modification implementation of chute plate was simultaneously applied. Significant time savings have been achieved with minimum investment.