Design of new die holder system for reducing die exchange time on 1000 ton hot forging press

Siddique, Muhammad Ahmad
In the forging industry, one of the main challenges is the reduction of setup change time which is non-productive time on the forging press. Long non-productive time reduces efficiency and affects profitability of the forging companies. In this thesis study, firstly setup change activities on the 1000 ton forging press of a forging company are observed and analyzed. With the help of these observations, it is seen that the new die holders with cassette holders and the new cassettes are required to reduce the setup change time radically. Different design versions of the new die holders have been studied. A new pair of die holders is designed and manufactured along with the new cassette holders and the new cassettes which hold the forging dies. The factors related to internal setup change operations, which are identified during the time and motion studies and root cause analysis, have been considered during design of the new die holder system. Several motion and time studies have been conducted to determine the average setup times for usage of new system. The average setup times for the new die holders and the previous die holders used in the particular forging company are compared and considerable reduction in setup time has been achieved. The time spent in mounting and aligning the die-cassette pairs on the die holders is significantly reduced during setup change by the help of the new die holder design. The motion and time study is concentrated on the internal setup change activities other than heating of the dies and cleaning of the forging press. By considering this way, 84% of reduction for the internal setup change time for the die holders with 2 die-sets and 62% of reduction for the internal setup change time for the die holders with 3 die-sets have been achieved on average.


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Citation Formats
M. A. Siddique, “Design of new die holder system for reducing die exchange time on 1000 ton hot forging press,” M.S. - Master of Science, Middle East Technical University, 2014.