Gerald Davis Design and Consulting

Gerald Davis

Contributing Writer
Gerald Davis Design and Consulting

Some 'near-jig' ideas

July 25, 2002

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In-process sampling and between-process checks can prevent problems at the production stage. Although using an inspection jig can be costly, some testing approaches that are not as rigorous as using an inspection jig are: stacking and blocking a sheared batch in order to scan the batch for variations; weighing castings; touring a customer's facility; and doing small batch inspections.

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Organizational planning

March 28, 2002

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The author discusses the importance of eliminating duplicated responsibilities, even in small job shops. The effectiveness of a company is improved when each person is responsible for specific tasks.

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Emotional thrills

February 28, 2002

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When you ride a roller coaster, you know that it is supposed to be fun and will last only a frew minutes. The job shop you're working in isn't supposed to be anything like a rollercoaster ride.

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An industry perspective

February 14, 2002

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On the positive side, job shops continue to be innovative and improve productivity; materials and software are improving; entry-level positions normally can be filled.

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Punching tips

December 13, 2001

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The author discusses what not to do to manage slug ejection. He mentions several tooling maintenance errors that he has made over the years, as well as what machine operators can do if they want to experience slug ejection difficulties. He concludes by stating that the easiest solution to slug management is to keep the tooling in good condition and to use the correct die clearance for the material.

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Design tips for sheet metal: Bend relief, small holes, hole distortion near bends, and minimum flange widths

October 25, 2001

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The article discusses making small holes and when to use a punch or laser cutter, inside radius measurements and how they differ depending on whether you are coining or air bending on a press brake, and adding bend relief to prevent tearing material.

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