Page 28 - MetalForming January 2014

We Put a Press
The key is managing and optimizing overall equipment effectiveness (OEE) and driving capacity gains. The press- room boasts five big transfer presses and six progressive-die presses. New additions include a 2900-metric-ton Schuler transfer press (not yet ready for prime time when we recently visit- ed the plant), a 630-metric-ton Kaiser mechanical press and a 160-ton high- speed Minster.
Progressive dies churn out stamp- ings as thick as 7 mm, but more typi- cally run 1-mm steel stock to stamp torque-converter blades, sheetmetal rivets and other small parts. This sce- nario is most typical of the lower-tonnage Minster and also on a 125-metric-ton high-speed Bruderer press “designed for speed,” says Gray. Rated to 800 strokes/min., the Bruderer turns out converter blades at 400 strokes/min., producing as many as three blades per hit.
The new Kaiser press, mean- while, makes the firm’s most tightly tolerance compo- nents, such as adjuster
rings and sensor rings
for clutches. These and other clutch compo- nents ship to a LuK assembly plant in Mex-
ico. Sensor rings, stamped from 1.5-mm- thick steel, carry dimen- sional tolerances as tight as 0.1 mm.
“They require a true die, and a
A sense of urgency permeates the LuK pressroom, driven in part by holding press operators accountable for meeting established OEE goals. Each operator workstation includes monitors (left) where they can enter production data and track perform- ance. And, to help operators quicken die changeovers, their tool cache (above) has been streamlined and neatly organized.
true press,” notes Gray, “and that press is unbelievably true. From the way the gibs and ways are designed to the robustness of the frame, it’s one solid press.”
An Overall QDC Strategy
It’s the new Minster press that Gray’s team added to the plant, for
26 MetalForming/January 2014
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Gray demonstrates the tight turning radius of the Rico die cart, allowing it to access the firm’s new 160-ton Minster high-speed press
(background). The cart is outfitted with a pair of hooked arms (left) that wrap around steel loops
LuK bolted to 150 of its dies. LuK also uses the cart to changeover the Bruderer press, which has shaved at least 2 min. from its changeover times com-
pared to using a tow motor.