Machine and Tool Maintenance for Stamping Plants

Presses and dies run through one module, one lifecycle and one report. A tool accumulates strokes against its configured life, so it surfaces as approaching, due or overdue against a tolerance you set, and completing preventive work resets that counter while the lifetime total keeps running.

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Covers
Presses and dies, one activity at a time on either
Tool trigger
Strokes against configured life, with an overdue tolerance
Machine trigger
Raised by a person, reactive or booked
Lifecycle
Assigned, accepted, in progress, completed
Every transition
Actor and timestamp recorded
Durations reported
Response, preparation, work, and end to end

In the product

The half of maintenance that needs no one to notice it. Everything past 100 percent of rated life is drawn as overflow.

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
Tool maintenance, one boardSample activities
  • Assigned
    D-2244Cover plate
    MW-3081
    Corrective

    Raised at 388% of rated life

  • Accepted
    D-2047End bracket
    MW-3084
    Preventive

    Owner accepted, awaiting a slot

  • In progress
    D-2116Terminal blade
    MW-3086
    Corrective

    In the tool room since 06:20

  • Completed
    D-2158Clamp washer
    MW-3072
    Preventive

    Counter reset, 214,880 strokes since last

What it does

Corrective and preventive action
CAPA as first class activity types, each with the full lifecycle and an audit trail on every transition.
Tool work due on strokes
Every stroke counts against the tool's life. Approaching, due and overdue surface against a tolerance you set, not a date in a diary.
Measurable service intervals
Strokes are snapshotted when an activity is raised, so the work done between one service and the next is a number.
One board with production
Maintenance is counted beside running presses, because a press held for a die change is unavailable in the same way a breakdown is.
Re-diagnosis is recorded
Changing a job's type demands a written reason, and the report shows how often the first call was wrong.
Four durations, not one
Time to accept, to start, to fix and end to end, each averaged, so a slow response is not hidden inside a slow repair.

How it works

  1. Raise the activity

    On a tool crossing its stroke threshold, or on a press when someone opens the job.

  2. Accept and start

    The owner accepts, then starts. Sending a started job back to accepted requires a written reason.

  3. Complete

    Preventive completion on a tool resets its counter and stamps the service date. The lifetime total keeps running.

Who this is for

  • A maintenance head whose breakdown history lives in a notebook.
  • A plant that services dies on a fixed calendar regardless of use.
  • An operation that cannot say how long its last ten repairs took, or how long they sat before anyone started.

Questions

Do you support CAPA?
Corrective and preventive are first class activity types, each with the full lifecycle, a mandatory reason on reclassification and an audit trail on every transition. There is no structured root cause form: what is captured is the description, the typed note log and who changed what, when.
Is machine maintenance triggered automatically?
No. Tools have a meter, which is the stroke count, so tool work becomes due on its own. A press has no equivalent meter, so machine work is raised by a person, either reactively or as a booked window.
Is predictive maintenance included?
Not today. The sensor chain already carries energy, pressure, air flow and temperature, which is the groundwork for it. Current alerting is threshold based on tool life.
Can maintenance block production?
Yes. An open activity is an absolute block on that press or that die in scheduling, whatever the time window, so nothing can be planned over it.
Do you report MTTR?
Time to repair is reported per activity and as an average, split four ways. It is raise to close wall clock, with no working hours subtracted. Mean time between failures is not calculated.

Related

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.

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