Quality and Setup Management for Stamping
Setup and quality are one chain. Each asset, product and tool combination carries its own setup parameters, prerequisites and instruction document, so the right configuration is defined before a run starts rather than remembered. Defects and scrap are categorised against a master list and feed the quality ratio in OEE.
- Parameter types
- Boolean, numeric, range, categorical, text
- Result zones
- Pass, partial, fail
- Range types
- Between, greater, less, greater equal, less equal
- Setup documents
- PDF instructions per asset, product and tool
- Prerequisites
- Completed in sequence before a run
- Feeds
- Quality ratio in OEE
In the product
One measured value against a target, showing the band between tolerance and the absolute bound.
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.
| Work order | Product | Pass | Partial | Fail | Critical |
|---|---|---|---|---|---|
| SFG0151_08 | Contact plate | 2 | 0 | 0 | 0 |
| SFG0015_07 | Cap inner big | 0 | 1 | 1 | 1 |
| SFG0041_07 | Retainer valve | 1 | 1 | 0 | 0 |
| SFG0009_08 | Bo-stator | 1 | 0 | 0 | 0 |
Partial means outside tolerance, inside the absolute bound
What it does
- Three result zones
- Pass, partial and fail, so a usable part is not thrown away and a bad one is not passed.
- Critical parameters
- A critical failure escalates the overall result; a non critical one is recorded without doing so.
- Setup parameters per combination
- Targets, tolerances and absolute bounds defined for each asset, product and tool.
- Instruction documents
- A setup PDF attached to the combination and opened by the operator at the machine.
- Prerequisite tracking
- Material, tooling and compliance conditions confirmed in order before production.
- Defect and scrap categorisation
- Recorded against a master defect list with severity, then reported and exported.
How it works
Define the combination
Asset, product and tool together, with parameters, tolerances and the instruction sheet.
Confirm before the run
Prerequisites are completed in sequence, each one recorded with who and when.
Check at the machine
The operator records values on the panel and gets the result immediately.
Who this is for
- A shop scrapping usable parts because the system only knows pass and fail.
- An operation where setup sheets live in a binder next to the press.
- A quality head who needs first off results tied to the work order.
Questions
- What does partial actually mean?
- Outside the tolerance band but inside the absolute bound. It is recorded as its own outcome.
- Can a partial still fail the order?
- Yes, if the parameter is marked critical. That is the point of the flag.
- Where do operators see the setup instructions?
- On the shop floor terminal, attached to the exact asset, product and tool combination.
- Do quality results affect OEE?
- Yes. The quality ratio is derived from recorded results and rejections.
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.
Book a walkthrough