During the roll forming process, many activities are performed simultaneously. Many people, especially newcomers to this type of manufacturing, are overwhelmed by the high production speed and mold complexity.
Don't be disappointed, even experts have a lot to learn. Just ask any machine manufacturer which manufacturing or system concepts are standard for the industry or can be used all the time. You will receive a variety of answers, which will surprise you. Each cross-section, each machine and each tool has its own characteristics.Let us look at some tools that can better define the rolling process. Our goal is to decompose the entire roll forming system into its components so that you can view, troubleshoot and improve the components to achieve the best performance. For many years, the same practices have been followed in areas such as improvement of industrial engineering standards, and it has continued to the latest lean manufacturing theory.
This exercise divides the entire roll forming process into four main categories:
• Machines (including all facilities required for the process)
• Material
• Manpower
• Method
If all four factors are optimized, you will have a perfect process, which means that the process will be performed at the highest level. When you look at the details of each roll forming process, ask yourself:
• What are the four elements of this process?
• What is the optimal level of each element?
• What needs to be done to achieve the best level?
You might call it common sense and just look at your process. Go out on the floor and check it out. Correctly understand the current state of the production line (you may need to wear it for this occasion). Many times, you will hear the operator's "I think it looks like ...". This is not good enough. Know the facts. Take pictures. Contact your operator and maintenance personnel.
Essentially, you need to follow the steps below to check all the facilities involved in the process:
1. Check for abnormal noise levels and strange noises.
2. Check the grease point.
3. Look for wear marks on machine parts.
4. Check that all bolts are in the correct position and tighten.
5. Make sure the layout is correct.
6. Make sure that the feed to the machine is normal.
7. Check whether the lubricant is used correctly and the filter is clean.
8. Check the preventive maintenance records on the machine.
You also need to check all raw materials in detail and ask the following:
1. Does the existing material meet the specifications?
2. What are the changes in raw materials? Can these changes still produce parts and print them efficiently?
3. Are there slight differences between different batches of raw material batches? What has changed from the beginning to the end of the coil?
4. Do I use the correct lubricant? How to maintain the correct level?
5. Have I checked how the coil is inserted into the system and how to remove the finished product?
6. Where is the work-in-process storage stored and how much?
Manpower does not represent a specific gender; it just moves material forward.
In this step, you need to analyze the human factors of the process:
1. Is this person physically fit for this job? Is the operator healthy and able to lift the required weight?
2. Does this person have sufficient knowledge and experience?
3. Are the personnel engaged in this work within all applicable safety limits?
4. Does the operator comply with established work standards in terms of movement and work steps?
5. Does the person work seriously?
Now, you should check the overall operation to define the status:
1. Are the working standards correct?
2. Has the work standard been reviewed and updated recently?
3. Are there potential safety hazards or even critical safety hazards in the operation?
4. How does the material flow into the machine, through the machine, out of the machine and into the next process? Do all materials move linearly?
5. Is the material handling equipment suitable for the process? Is it sufficient for the next step?
6. Are there other ways to stack parts to minimize scrap and reduce machine load on subsequent processes?
7. Is the machine installed correctly?
These are some of the many questions you should ask yourself. In short, no matter how terrible the process is, you never have to be afraid to face the facts.In most cases, the problem can be traced to machine setup, maintenance or electrical problems. Here are some items you might want to include in the list:
• Check whether the roll forming coolant is not applied or not turned off in the critical forming pass.
• Check the breaking pressure of the uncoiler and the free-spinning reel. Ensure that the material is not pulled back during operation.
• Check the film setting according to the setting chart.
• Check tooling records.
• Check whether the punching tool moves freely on the material.
• Check the lineup of inlet equipment and material guides in the rolling mill.
• Check the forming gap with wire, or check the applied pressure against the installation drawing.
• Cut out slice samples from the mill and check them (use a template for critical passage).
• Check the function and location of electronic sensors.
• Check punching process.
• Check the condition of the mill; ensure that the shafts are properly aligned within and between the channels.
• Check drive components; worn belts are often overlooked.
