Tool Shop Optimization:

Keeping The Die Industry Competitive

Todays Speakers

Sam Golan, CEO &

President, Cimatron

Peter Ulintz, Advanced

Engineering & Process
Developer

Alan Zielinski,
Cimatron

How to Submit Questions

Click on the Q&A tab at the top of your

screen
Type question
Click ask
Questions will be addressed as time permits at
the end of the session
All unanswered questions will be answered
via email following the session
3

How Lean Manufacturing Can Help

the Die Industry
Sam Golan, Cimatron
CEO & PRESIDENT

sg13

Agenda
Lean Manufacturing buzz or real?
The pains in our industry
How Lean Manufacturing will optimize your die shop

Lean Manufacturing
Whats all the buzz about?

Lean manufacturing

WMS

Agile

APS

Six Sigma

TQC

Lean Six Sigma

ERP

TQM

CFM

KAIZEN

TCO

JIT
KANBAN
MRP
PLM
6

(This is only a partial list)

Lean Manufacturing
Lean manufacturing is a management philosophy focusing on
reduction of the seven wastes to improve overall customer value:
Transportation
Inventory
Motion
Waiting time
Over-production
Processing Itself
Defective Product (Scrap in manufactured products or any type of
business.)

By eliminating waste, quality is improved, production time and costs

are reduced.
7

Cimatron and Lean Manufacturing

Quoting to Delivery
A recommended business, engineering and manufacturing
process and flow

Tool Shop Optimization the three Ws

What you get?
What do you do with it?
Who gets it?

Objectives
Increase productivity
Shorten delivery times
Reduce cost
Control engineering changes
Increase customer satisfaction
Increase employee motivation
9

sg14

Manufacturing Industry Pains

6
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2
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Source: CIMdata

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Staying Competitive
Increasing employee
motivation is also
important
The primary focus is to
implement enhanced
technology

5.2%

Improving employee
training

15.6%

53.2%
Improving or changing
processes is a strong
secondary focus

11

Source: CIMdata

26%

sg15

Manufacturing Industry Pains

Source: CIMdata

6
De

5
4

ry
e
liv

ity
l
ua
Q

s
o
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Ch

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B
As

2
1
They are all linked to each other and developed over time

12

sg17

Assistance

Breadth

Compatability

Service

Flexibility

Technology

Stability

Changes

Cost

Quality

Delivery

Industry Pains The Root Causes

2
1
0
1
They are all linked to each other
and developed over time

13

Process & Flow

Multiple Systems
Multiple Vendors
Quality of Support
Advanced Training

Common Pains
Problems
Bottleneck in
plate
machining
Design work
takes too
long, missing
delivery times
EDM design
and
programming
takes too long

14

Common Medication
Problems

Solutions

Bottleneck in
plate
machining

Buy additional
machine

Design work
takes too
long, missing
delivery times

Outsource
design work

EDM design
and
programming
takes too long

New seat of
software
+
New
electrode
added
software
personnel

15

Common Results
Problems

Solutions

Bottleneck in
plate
machining

Buy additional
machine

Huge capital investment

but still do NOT see great
results
INCREASE IN COST

Design work
takes too
long, missing
delivery times

Outsource
design work

EDM design
and
programming
takes too long

New seat of
software +
added
personnel

16

Results

Design time is shorter but overall

delivery times still too long due to
communication issues
EDM production time is shorter but
overall PROCESS SLOWER due to
increased in data translation and
manual processes

What is missing?

17

Analysis before investment

Problem
Bottleneck in
plate
machining
Design work
takes too
long, missing
delivery times
EDM design
and
programming
takes too long
18

Analysis = Process, flow &

optimization
Problem
Analysis
Bottleneck in
plate
machining
Design work
takes too
long, missing
delivery times
EDM design
and
programming
takes too long
19

What do you get?

What value you add?

Who gets it?

Customer Data Management

UG, Catia,SDRC, solid works, AutoCAD,

Quoting
Manual plus Engineering

Major Changes

Outsourcing 40%
of design work

2D Prints for
Prelim Approval
(system #5)

1 Week

Major Changes

In-House Prelim
Design (20%)
(System #4)

Review Approval
With Notes From Customer
Update Concepts
Per the Review Notes
(Outsource 80%)

Internal Review
Meeting with Notes
Complete die Design
(Outsource 80%)
IGES
IGES File

EC1
IGES

Form die Machining

(system #1)
- Manual Setup Sheets
for Each Setup
-Manual Tool Set Up
Sheet

20

EC2
IGES
Wire EDM
(system #2)
Import 2D data
-Errors
- Redundancy

Update Concepts
Per the Review Notes
(In-House 20%)

Complete Die Design

(In-House 20%)

EC3
IGES

Trim Punch & die

(system # 1)
-Detailing
-Manual Set up
Sheets for Machining

2D Plates Detailing
(system #3)
Manual Set up
High cost of ECO
(35% utilization)

Current
Process & Flow
18 Week Product Delivery

Customer Data Management

UG, Catia,SDRC, solid works, AutoCAD,

Quoting
Manual plus Engineering

Major Changes

Outsourcing 40%
of design work

2D Prints for
Prelim Approval
(system #5)

1 Week

Major Changes

In-House Prelim
Design (20%)
(System #4)

Review Approval
With Notes From Customer
Update Concepts
Per the Review Notes
(Outsource 80%)

Internal Review
Meeting with Notes
Complete die Design
(Outsource 80%)
IGES
IGES File

EC1
IGES

Form die Machining

(system #1)
- Manual Setup Sheets
for Each Setup
-Manual Tool Set Up
Sheet

21

EC2
IGES
Wire EDM
(system #2)
Import 2D data
-Errors
- Redundancy

Update Concepts
Per the Review Notes
(In-House 20%)

Complete Die Design

(In-House 20%)

EC3
IGES

Trim Punch & die

(system # 1)
-Detailing
-Manual Set up
Sheets for Machining

2D Plates Detailing
(system #3)
Manual Set up
High cost of ECO
(35% utilization)

Customer Data Management

ONE system
Quoting
(E concept Pro)

Outsourcing Prelim
Design Work (20%)

In-House Prelim
Design (80%)
2D Prints for Prelim Approval
60% is not needed
Review Approval
With Notes From Customer

Update Concepts
Per the Review Notes
(Outsource 20%)

Update Concepts
Per the Review Notes
(In house 80%)
Internal Review
Meeting with Notes

Complete Die Design

(Outsource 20%)

Complete Mold Design

(In House 80%)

Manufacturing
- Template Machining
- EDM optimized
- Auto Detailing
- Setup Sheet & Reports
- Shop Floor Viewers

22

Proposed
Process & Flow
12 Week Product Delivery

Customer Data Management

ONE system
Quoting
(E concept Pro)

Outsourcing Prelim
Design Work (20%)

In-House Prelim
Design (80%)
2D Prints for Prelim Approval
60% is not needed
Review Approval
With Notes From Customer

Update Concepts
Per the Review Notes
(Outsource 20%)

Update Concepts
Per the Review Notes
(In house 80%)
Internal Review
Meeting with Notes

Complete Die Design

(Outsource 20%)

Complete Mold Design

(In House 80%)

Manufacturing
- Template Machining
- EDM optimized
- Auto Detailing
- Setup Sheet & Reports
- Shop Floor Viewers

23

How Do We Get There

Cimatron developed an eight-step methodology
Step 1: Identify the best process and flow
Step 2: Streamline internal and external communications
Step 3: Implement integrated 3-D design and manufacturing
Step 4: Re-examine outsourcing
Step 5: Plan for success
Step 6: Acknowledge the cost of change
Step 7: Get buy-in
Step 8: Measure results
24

Thank You!
E-mail additional questions to info@cimatrontech.com
call 248-596-9700
or visit www.cimatrontech.com

Peter J. Ulintz
Advanced Product Engineering Manager
Anchor Manufacturing Group, Inc.

Historical Overview
1960s
The die maker:
z receives a part print
z creates a flat blank and develops a strip layout
z designs a tool to produce the required part
z creates necessary sketches and machines almost all die components
z assembles the tooling and conducts die tryout
1970s
The die maker:
z receives a part print
z receives a die layout
z fully dimensions the die layout and creates sketches for machining
z oversees the machining of all components; apprentices, machinists, specialty
machine operators (NC tape and duplicating)
z assembles the tooling and conducts die tryout

27

Historical Overview

1980s
The die maker:
z receives several part prints
z receives several CAD generated die layouts
z 3-axis CNC programs and WEDM programs generated in engineering
z creates necessary sketches for manually machined components
z oversees the machining of all components; apprentices, machinists, specialty
machine operators (WEDM, 3-axis CNC)
z assembles the tooling and conducts die tryout

28

Historical Overview

1990s
The die maker:
z receives several tooling programs
z receives a fully detailed die assembly drawings
z receives 100% fully detailed die components
z die components are processed in utilizing production job shop methods and a
project manager
z die shop floors are reconfigured to handle the new process methods
z die maker receives fully machined die components
z die maker assembles the tooling and conducts die tryout

29

Historical Overview
TODAY
The die maker:
z is becoming OBSOLETE
z is being replaced by the die engineer, die assembler and metalforming specialists
The die engineer:
z is responsible for all process engineering, including: metalforming simulations,
material cost optimizations, pre-build process validation, tool weight reduction,
process robustness and reliability
The metalforming specialist:
z is responsible for circle strain analysis; controlling material properties; establishing,
maintaining and controlling process parameters; correlating simulation results with
the final manufacturing processes; and implementing advanced process control
techniques such as Statistical Deformation Control (SDC)

30

Designing vs. Engineering

DESIGNS
z are nothing more than opinions
z are conceived or fashioned in ones mind
z are, more often than not, unique creations
z are based on personal experiences, including fears
z are the result of acquiring and applying EXPERIENCE
People who create, invent, or design have deep personal attachments to their
work. Design related problems are dealt with emotion.
ENGINEERING
z is based on science and mathematics
z the fundamental principles of science and mathematics are applicable across a
broad spectrum of problems not just the one we have experience with
z Is the result of acquiring and applying KNOWLEDGE
People who engineer things are governed by the principles of science and
analytical results. Engineering related problems are dealt with data.

31

Designing Method
Part Inspection

Die Set Up
Die Tryout

Decision

Not OK

Design &
Build Tooling

OK

Production

Die / Process Modifications

32

Transitional Methods
Analyze Results

Computation

Decision

Not OK

Initial Product or
Process Design

OK

Modify Input Parameters

Final Product or
Process Design

33

Transitional Methods
Blank Size Engineering
Product

Forming Limit Diagram

Quoting
Sheet

Cost Optimization

Blank Outline

To Remain Competitive
Most progressive companies will have blank
development and quoting software.
Courtesy of FTI (FormingSuite)

34

Engineering Methods
Computer
Computer

Analysis
Objectives

Die Engineer

Computation
Decision
Not OK

Initial
Design

OK

Modification

Final
Optimized
Design

Design Parameters
35

Engineering Methods
AN EXAMPLE:
A die structure is engineered based on loading conditions, load
path, force distributions, tooling deflections, machine deflections,
vibrations and damping
The die is engineered based on the need of the process not the
feelings or experiences of the designer

36

Load Case for Die Structures

z

Forming Loads
z Stamping Contact Forces
z Dynamic Inertial Loads
z SPM (Strokes per
Minute)
z Transportation Loads
z Lift
z Mount

Courtesy of Altair Engineering

37

Die Structure Optimization

Original Die Design

with traditional
patterns

Design Space and

Load definition

Optimized structural
ribs

Topology
Optimization

Geometry Extraction

Results layout
38

Engineering Methods
IS THERE REALLY A NEED
FOR ALL THIS?
HOW WILL YOU HANDLE NEW MATERIALS
AND THE FORMING PROBLEMS THEY POSE IF
YOU NEVER ENCOUNTERED THEM BEFORE?

39

This is NOT Springback

Courtesy of International Iron and Steel Institute

40

Where do you start with this?

Unbending

Wall Curvature

Opening

Twisting

From EuroPAM2004 Arcelor & Renault

41

The Next Great Leap

Virtual Production: Sensitivity Analysis

Displacement in Z-direction

Courtesy of AutoForm

42

Sensitivity Analysis
Springback response out of control

z
z
z

A passing part may show

instability with varied inputs
Springback does not repeat
No trend relating input variation
to springback response
Compensate to thisschedule
lots of overtime during tryout
Distance from net

Courtesy of AutoForm

Noise Variable

43

Sensitivity Analysis
Springback responses in control
z

Distance from net

In control process
shows stable
relationships
z Inputs:outputs
z Compensate to this
design, sell your
die easier

Courtesy of AutoForm

Noise Variable
44

Challenges
HOW DO WE STAFF AND TRAIN FUTURE ENGINEERS?

IS THE U.S DIE INDUSTRY HEALTHY ENOUGH TO BURDEN THE COSTS

TO TRANSISTION TO ENGINEERING DIES?

SHOULD WE SIMPLY BUY OUR TOOLING FROM OVERSEAS AND SAVE

OURSELVES THE HEADACHE?

45

Thank You
z For

additional questions

Email pete.ulintz@toolingbydesign.com
z Or visit toolingbydesign.com
z

46

CAM Tool & Die, Ltd.

Richmond Hill, Canada

Arpad Takacs, Founder

Company Profile
{
{
{
{
{
{

250,000 sf divided between 3 facilities

70+ Million Dollars in Sales
340+ employees
45 tools per year
OEM, Tier 1 & Tier 2 suppliers (Jaguar, GM, Chrysler)
Large progressive & stamping dies - automotive

48

Company Goal:
100% Customer Satisfaction
{

How to achieve this goal?

z
z

Educate your employees

Use the latest technology
{

z
z

Focus on quality of products

Offer a full range of services for customers
from initial design to the finished product
{

I.e. Cimatron

Cam Tool can go from concept to prototype to complete

hard tooling all within their manufacturing facility

Have the ability to take jobs others cannot

handle

49

Streamline Internal Processes

We can get a file part from the customer,

design a die around it, machine the blocks,

make engineering changes to the part, and
build the die from beginning to end all in
the same single software package.
- Jay Weiner, Mechanical Engineer and IT
Manager, CAM Tool & Die

50

CAM Tool & Dies Infrastructure

{

Uses state-of-the-art machines

z
z
z
z
z
z

Including thirteen presses with capacities

ranging from 400 to 1,600 tons each
Feeders and Decoilers handle 72 coils
from .123-.250
3 advanced linear transfer systems
Resistant and robotic mig welding
Full lab capabilities to inspect welding
5-axis laser and milling capabilities

Cimatron E CAD/CAM software on

an infrastructure that utilizes
multiple computer operating
systems
z

z
z
z

Allows Cam Tool to assume the

simulation, design, and production of
some of the most complex dies used for
automotive stamping
Have worked with Cimatron for 20 years
Relationship is a partnership
Works closely with the Cimatron
engineering team and provides input
51

Handle Any Job

We take jobs that others tell their customers
Chrysler, Ford, GM they cannot be
done. We are able to take jobs that other
shops are scared to take because they
dont have the capabilities to turn a quality
job at a reasonable time and cost.
- Jay Weiner, Mechanical Engineer and IT
Manager, CAM Tool & Die

52

How CAM Tool Uses CimatronE Die Design

{
{

{
{

CAM tool uses the strip layout portion of the Cimatron

Die Design module to make quoting fast and accurate.
accurate
Cimatrons Analysis Tools help give Cam Tool engineers
indications of expectant problems in forming during the
quoting process.
Cimatrons 3D strip layout uses a simple 2D pick &
punch procedure for defining trim steels.
Creation of Cam Tool standard die sets that adjust to
the size of the strip is easily accomplished with
Cimatron.
Local Blank and Blank to Binder enables Cam Tool
engineers to determine trimming conditions during
intermediate forming stages.
Bending tools in Cimatron makes doing overbends
quick and easy.
53

Die Skin, Quick Blank and FEA Analysis in Seconds!

54

Nesting with Blank, Scrap and Progression Area Calculations.

55

CimatronE Die Quote

56

CimatronE Die Quote setup sheet

57

Link to 3D strip and form shapes.

58

Strip information automatically generated.

59

Tooling information of CimatronE Die Quote.

60

Selection of punch unit styles.

61

.
62

Trim and form dies and punches estimated from 3D strip.

63

Die and punch costs automatically populated from 3D model.

64

Estimation of die unit costs generated from 3D model.

65

Die unit costs automatically populated into CimatronE Die Quote

66

Die costs automatically calculated via 3D model using customer

defined variables

67

Safety Zone Analysis displaying Wrinkling or Failure

Tendency.

68

Thickness Strain Analysis displaying material strain due to

thickening or thinning of material.

69

Simple, 2D indication of trim steel area.

70

Locating trim punch area on strip.

71

Strip is punched and first instance is marked as a punch.

72

Finished strip with trim steels & form punches highlighted.

73

Selection of customer-defined standard die set.

74

Placement of standard die set (notice die set is too long and
too narrow).

75

Alteration of parametric dimensions.

76

Die set adjusts to strip dimensions.

77

Exploded view of die set and strip.

78

Selection of planar face to unfold flange to.

79

Selection of flange geometry to locally blank.

80

Material and blanking parameters to determine accurate

blank profile.

81

Flange geometry locally blanked.

82

Further localized blanking example.

83

Surfaces selected defining binder surfaces.

84

Surfaces to be blanked.
85

Instant analysis to determining formability.

86

Material and blanking parameters.

87

Final geometry Blanked to Binder.

88

Part to bend, with normal plane and bend line.

89

Selection of geometry and direction of bend.

90

Side view prior to bending.

91

Right side bent.

92

Bend side toggled to include left side.

93

Finished product including overbend.

94

How CAM Tool Uses CimatronE Die Design

{

CAM tool uses the strip layout portion of the

Cimatron die design module to make quoting fast
and accurate.
accurate
Cimatron analysis tools give an indication of where
to expect problems in forming which helps in the
quoting process.

95

How CAM Tool Uses CimatronE Die Design

{

{
{

CAM tool uses the strip layout portion of the

Cimatron die design module to make quoting fast
and accurate.
accurate
Cimatron analysis tools give an indication of where
to expect problems in forming which helps in the
quoting process.
The bending and twisting tools in CimatronE Die
Design make doing over-bends quick and easy.
easy
The local blank and blank on binder help us
determine how we will trim during intermediate
forming stages
In CimatronE Die Design, you can easily create
standard die sets.

96

Communication is Key
We communicate our needs, and Cimatron has
stepped up with the type of responsiveness that
we need in order to deliver the best results to
our customers. Somehow, they always find
ways to make things possible.
- Arpad Takacs, Founder, CAM Tool & Die

97

Thank You!
www.camtooldie.com

98