The Fabricator May 2006

Like the molds he repairs, Five Star Tool Welding owner Joe Canfield finds that the welding equipment he uses at his company is getting smaller and smaller. Over the years GTAW equipment has evolved to better meet the needs of its tool and die welding users.

In 2005 precision stamper Weiss-Aug of East Hanover, N.J., achieved a reject rate of less than 1 part per million. The company credits the success to meticulous planning and almost flawless execution. Such an approach applies for Weiss-Aug even when it comes to uncoiling metal.

Roll forming of roofing components for the pre-engineered building and component industries presents unique challenges for manufacturers. Tighter profile tolerances, wider product ranges, and compressed lead times present production challenges for producers running older equipment or those contemplating a move into this market. Some developments in equipment and processes that are important to producing secondary structural members include quick-change roll form tooling systems and tooling that can improve the productivity of roofing components- Cee's, Zee's, Eave Struts, Channel, and Base Angle.

The use of high-strength steels (HSS) and ultrahigh-strength steels (UHSS) has made stamping complex structural automotive components increasingly difficult and capital-intensive. Changing from traditional stamping (at room temperature on a mechanical press) to hot stamping (at elevated temperatures on a hydraulic press, with a water-cooled die for quenching) provides a suitable alternative for OEMs that produce these challenging parts.

Cosma International applies its own hot-forming technique to stamping automotive metal components such as A and B pillars, roof headers, roof rails, rockers, door intrusion beams, and bumpers, to meet new CAFE standards for weight, NHTSA requirements for strength, and to counter problems with springback in UHSS components.

This article is adapted from a report analyzing the results of a manufacturers' survey. It discusses the common quality challenges all manufacturers and explains what best-in-class manufacturers are doing with quality control to set themselves apart from the competition.

Once you have your contract and have delivered product on time and within specifications, it's time to find out how to get paid in a timely fashion.