{"id":3685,"date":"2022-03-14T16:40:01","date_gmt":"2022-03-14T15:40:01","guid":{"rendered":"https:\/\/sw.fst.com\/magazine\/?p=3685"},"modified":"2022-03-15T11:28:00","modified_gmt":"2022-03-15T10:28:00","slug":"neither-scrap-nor-100-percent-inspections-thanks-to-a-new-geometry","status":"publish","type":"post","link":"https:\/\/sw.fst.com\/magazine\/en\/2022\/03\/neither-scrap-nor-100-percent-inspections-thanks-to-a-new-geometry\/","title":{"rendered":"Neither Scrap nor 100\u00a0Percent Inspections Thanks to a New Geometry"},"content":{"rendered":"\n

A lean project at the stamping plant in Weinheim, Germany, has simultaneously improved quality, productivity and on-time delivery. Freudenberg Sealing Technologies (FST) has honored it with the Lean Systems Award Europe.<\/p>\n\n\n\n

Nearly 1.2 million metal parts, individually checked by hand. It takes little imagination to understand that the process takes a massive amount of repetitive, manual labor. There is an urgent need to take action in our manufacturing process, if deformations are regularly found during the 100 percent inspection, and the defective parts are sorted out as scrap. In this case, the response took the form of a lean project lasting several days.<\/p>\n\n\n\n

\u201cThe problem was multilayered. Numerous causes were considered possible. So a systematic approach was required,\u201d said Dr. J\u00f6rg Avemann, Manager, Lead Center Stamping. The lean project\u2019s core team included Claudia Romanski, Lean\/GROWTTH, Guido Will, Quality Management, Gregor Kempf, Engineering, and fitter Peter Fieger, all from the Weinheim Stamping Facility. Over the course of the project, the team used methods from the \u201clean toolbox,\u201d among other options, but was able to draw on multifaceted support from the facility\u2019s employees and the tool shop as well. The interdisciplinary team worked out very well, contributed added value and was a key success factor for our project,\u201d Romanski said.<\/p>\n\n\n\n

\"\"
The core team of the lean project included (from left): Peter Fieger (fitter), Claudia \u00adRomanski (Lean), Dr. Philipp Stein (Operations Manager), Gregor Kempf (engineer), and Dr. Thomas Heep (Business Unit Manager).<\/figcaption><\/figure>\n\n\n\n

SHORTER THROUGHPUT TIMES<\/h2>\n\n\n\n

But first things first: \u201cAt the very start, during brainstorming, we came up with some possible reasons for the deformation,\u201d she said. \u201cThe geometry of the channel became the focus during a systematic analysis in which the metallic parts are shot with compressed air after stamping and forming. At the end of the channel, impact flaps slow the approaching metal rings and guide them on their way to the transport box. It turned out that the impacts on the channel led to damage, no matter what the stamped parts\u2019 trajectory was. In addition, an open edge in the parts\u2019 impact zone was not protected. It was possible for the rings to strike them and suffer damage.<\/p>\n\n\n\n

The ejection channel also needed a new design. Here the team is making valuable progress with the help of the 3P method (see box). The trajectory of the parts in the channel has been changed, the edge rounded, and the impact protection reinforced with three curtains. \u201cWith the new process, we do not need to inspect all the parts. This will greatly shorten throughput times. In monetary terms, we are saving more than 40,000 euros,\u201d Romanski said.<\/p>\n\n\n\n

There is another positive side-effect that falls into the \u201clessons learned\u201d and \u201ctransferability\u201d categories. Stamping plants in other FST facilities are taking advantage of the insights gained in Weinheim. Among other uses, these findings flowed into a new concept for an automated stamping cell, ACDC (see Sealing World 03_2021 as well as page 30 of this issue).<\/p>\n\n\n\n

\n

3P Method<\/h2>\n\n\n\n

The 3P Method is an approach to planning work areas three dimensionally. The best possible design is simulated with simple aids such as cardboard boxes and paper. Ideally, the employees due to work in the space are integrated into the planning process. This often makes it possible to see weak points ahead of time. They can then be corrected.<\/p>\n<\/div><\/div>\n

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\r\n \r\n <\/i>\r\n <\/a>\r\n <\/span>\r\n<\/div><\/div>","protected":false},"excerpt":{"rendered":"

A lean project at the stamping plant in Weinheim, Germany, has simultaneously improved quality, productivity and on-time delivery. Freudenberg Sealing Technologies (FST) has honored it with the Lean Systems Award…<\/p>\n","protected":false},"author":3,"featured_media":3440,"comment_status":"closed","ping_status":"closed","sticky":false,"template":"","format":"standard","meta":{"inline_featured_image":false,"footnotes":""},"categories":[74,78],"tags":[277],"powerkit_post_featured":[],"class_list":["post-3685","post","type-post","status-publish","format-standard","has-post-thumbnail","category-technology-innovations","category-weinheim-en","tag-edition-02_2022-en"],"_links":{"self":[{"href":"https:\/\/sw.fst.com\/magazine\/en\/wp-json\/wp\/v2\/posts\/3685","targetHints":{"allow":["GET"]}}],"collection":[{"href":"https:\/\/sw.fst.com\/magazine\/en\/wp-json\/wp\/v2\/posts"}],"about":[{"href":"https:\/\/sw.fst.com\/magazine\/en\/wp-json\/wp\/v2\/types\/post"}],"author":[{"embeddable":true,"href":"https:\/\/sw.fst.com\/magazine\/en\/wp-json\/wp\/v2\/users\/3"}],"replies":[{"embeddable":true,"href":"https:\/\/sw.fst.com\/magazine\/en\/wp-json\/wp\/v2\/comments?post=3685"}],"version-history":[{"count":1,"href":"https:\/\/sw.fst.com\/magazine\/en\/wp-json\/wp\/v2\/posts\/3685\/revisions"}],"predecessor-version":[{"id":3686,"href":"https:\/\/sw.fst.com\/magazine\/en\/wp-json\/wp\/v2\/posts\/3685\/revisions\/3686"}],"wp:featuredmedia":[{"embeddable":true,"href":"https:\/\/sw.fst.com\/magazine\/en\/wp-json\/wp\/v2\/media\/3440"}],"wp:attachment":[{"href":"https:\/\/sw.fst.com\/magazine\/en\/wp-json\/wp\/v2\/media?parent=3685"}],"wp:term":[{"taxonomy":"category","embeddable":true,"href":"https:\/\/sw.fst.com\/magazine\/en\/wp-json\/wp\/v2\/categories?post=3685"},{"taxonomy":"post_tag","embeddable":true,"href":"https:\/\/sw.fst.com\/magazine\/en\/wp-json\/wp\/v2\/tags?post=3685"},{"taxonomy":"powerkit_post_featured","embeddable":true,"href":"https:\/\/sw.fst.com\/magazine\/en\/wp-json\/wp\/v2\/powerkit_post_featured?post=3685"}],"curies":[{"name":"wp","href":"https:\/\/api.w.org\/{rel}","templated":true}]}}