The product, screen by screen.

Five of the surfaces an operator, a planner and a works manager use daily. Values are illustrative and internally consistent, drawn from a two shift run on a single press.

The live run

Read about stamping press monitoring

Cumulative parts and press rate on one time axis, with every stopped period marked. The flat stretches are the ones that cost money.

0live
Produced parts
80.4/ 90.0 SPM
Production rate
19,040live
Total strokes
Running
Machine status
05k10k15k20k9009:0011:0013:0015:00
RunningStoppedPartsRateTarget rate

Sample shift

Shift periods as a table
FromToStateDuration
08:4009:38Running58m
09:3810:12Stopped34m
10:1210:59Running47m
10:5912:35Stopped1h 36m
12:3513:04Running29m
13:0413:25Stopped21m
13:2514:27Running1h 02m
14:2715:53Stopped1h 26m
15:5316:35Running42m

Downtime, ranked then pivoted

Read about stamping press downtime analysis

Reasons ordered by duration, each carrying its share and its occurrence count. The same record re-reads seven ways.

State overviewBy reasonBy assetBy toolBy productBy departmentBy operator
219h 15m
Unplanned downtime, 30 days
Top 5 of 22 reasons
  • Power supply not available41h 23m
    18.9% · 16 stops
  • Coil loading22h 56m
    10.5% · 145 stops
  • Breakdown analysis17h 16m
    7.9% · 149 stops
  • Adjusting the setup15h 53m
    7.2% · 172 stops
  • Tool breakdown15h 28m
    7.1% · 27 stops

Die life against rated life

Read about tool and die management

Strokes done against strokes rated. Everything past 100 percent is drawn as overflow, because a calendar never told anyone to pull a die.

Tool life, strokes against rated life34 tools tracked
  • D-2244Cover plate388%Due
    1,164,811 of 300,000 strokes
  • D-2231-3Shutter frame385%Due
    1,924,402 of 500,000 strokes
  • D-2043Stator shroud335%Due
    1,005,874 of 300,000 strokes
  • D-2415Busbar link316%Due
    315,741 of 100,000 strokes
  • D-2158Clamp washer77%
    214,880 of 280,000 strokes

The press schedule

Read about stamping production scheduling

Presses on one timeline with setup drawn separately from production, so changeover is something you can plan around rather than discover.

Tuesday, one shift5 of 12 presses
08:0009:0010:0011:0012:0013:0014:0015:0016:0017:00
  • PR-112
    VPX-63
    RO-4426SetupRO-4423
  • PR-118
    VPX-R45
    RO-4402RO-4405
  • PR-124
    VPX-H45
    RO-4386SetupRO-4430
  • PR-131
    VPX-45
    RO-4417RO-4434
  • PR-137
    VPX-H35
    RO-4380RO-4409
CompletedIn progressSetupPartialNow

Quality, in three zones

Read about quality and setup management

A part outside tolerance but inside its absolute bound is recorded as partial, not scrap. The results table carries that column for real.

Formed heightTarget 12.40 mm · tolerance ±0.05 · absolute ±0.12
FailPartialPassPartialFail
12.48
12.2812.3512.4512.52

This part measured 12.48 mm. Outside tolerance, inside the absolute bound, so it is recorded as partial rather than counted as scrap. A critical parameter escalates a partial to a fail; a non critical one does not.

Quality check results, sample work orders
Work orderProductPassPartialFailCritical
RO-4417Terminal blade2000
RO-4398Housing cap0111
RO-4412Retainer ring1100
RO-4391Rotor spacer1000

Partial means outside tolerance, inside the absolute bound

See it on your own presses.

We instrument one press, run it for a month, and show you the shift record against what you thought was happening.

Book a walkthrough