TOOL ROOM

THEME : To Prevent frequent brakeage of piercing

punches

Before

AFTER

Breaking at
this point

PHYSICAL PHENOMENON : frequent breakage of piercing punches in 08E HMSI OP

(20 Occ / month).

Analysis :

Countermeasure : -

W1: piercing punch breakage

W2:.load on shank area
W3: sharp corner at shank taper area.
W4: weak at sharp corner.

By providing smooth radius at shank

taper area so that punch is
strengthened.

THEME : To Prevent breakage of die back up plate

Before

101/102 DIE BACK PLATE 30mm

THICKNESS

AFTER

101/102 DIE BACK PLATE 40mm

THICKNESS

PHYSICAL PHENOMENON : frequent breakage die back up plate in

101/102 OP (2 times)
Analysis :

Countermeasure : -

W1: die back up plate breakage

By increasing the thickness of die back

up plate from 30mm to 40mm, hence
back up plate is strengthened.

W2: not withstanding the load.

W3: less thickness

THEME : To Prevent frequent tool change due to

wear out

Before

AFTER

BUSH FORMING M/C (KBD) KNIFE NON

COATED

BUSH FORMING M/C (KBD) KNIFE ALCRONA

COATED

PHYSICAL PHENOMENON : frequent change of tool due to wear out .

(every 20kgs).
Countermeasure : Analysis :
W1: tool wear out
W2: low hardness

Knife working area is coated with

Alcrona, hence surface hardness has
increased.

THEME : To Prevent frequent TOOL CHANGE DUE

TO WEAR OUT

Before

KBD L . H & R .H TOOLS

AFTER

KBD L . H & R .H TOOLS WITH CARBIDE TIP

PHYSICAL PHENOMENON : frequent change of tool due to wear

out (500kgs ).
Analysis :
Countermeasure : W1:tool wear out.
W2:low hardness.
W3:tool material didn't support to get
high hardness.

Carbide insert brazed at working area,

hence working area got good hardness.

THEME : To prevent operator skill in clamping tool

Before

AFTER

PHYSICAL PHENOMENON : clamping tool with non standard clamps

getting loose in running causes tool break down.
Analysis :
W1:tool break down due to non
standard clamps.

Countermeasure : Provided direct clamping by providing

spacer and T clamp screw holes.

THEME : To prevent bush miss

alignment

Before

AFTER

PHYSICAL PHENOMENON : to prevent bush pilot breakage due to

miss alignment .
Analysis :
W1:bush pilot breakage.
W2:miss alignment between bush and
pilot.
W3:less clearance to align.

Countermeasure : Provided entry step to bush pilot , hence

it got 1mm per side clearance to align
bush with pilot.

CONVERSION OF D08N-O-RING
ASSEMBLY M/c to D08E MODEL
BEFORE

AFTER

As 8E Model order has increased and 8N O Ring M/C has less order M/c
has converted to 8E
ALL TRACKS
CHANGED

PIN ANVIL AND BUH

ANVIL

PIN GUIDE
ADDED

PIN CARRIER
HOLDER
CHANGED

Before

AFTER

Fork support is increased up to pin assembly stage.

Provided pin guide to assemble pin easily.

Pin carrier holder changed to use common pin carrier for all
machines .

CONVERSION Of 4C SOLID BUSH EXTRUSION

M/c to D088 MODEL PROPOSED & TAKEN TRAIL
Before

AFTER

As 4C Model order is less than M/C capacity, in order to use M/C in ideal time it is proposed to
convert it to 88 model

Before

4th PUNCH

AFTER

4th KO
PUNCH

4th DIE

4th PUNCH
HOLDER

4th KO PUNCH HOLDER

COLLET

4th PUNCH

4th KO
PUNCH

4th DIE

4th PUNCH
HOLDER

4th PUNCH HOLDER

COLLET

THEME : Difficulty in checking blanking

punches

BLANKING PUNCHS CHECKING

GUAGE PLATE

PHYSICAL PHENOMENON : difficulty in checking blanking

punches.
Analysis
:
Countermeasure : W1: difficulty in checking blanking
punches
W2: difficulty in checking profile
accurately

Implemented gauge plate to check

blanking punches easily and accurately.

Thank You