Category Archive: Progressive Die Stamping

Why ISO 9001:2015 Certification Is So Important in the Metal Stamping Industry

To ensure we provide only the highest-quality metal stamped products to our customers, Manor Tool & Manufacturing Co. is now ISO 9001:2015 certified in the following areas:

  • Manufacture of Precision Metal Stampings
  • Deep Drawn Stampings
  • Machined Components and Assemblies for Various Industries
  • Design and Construction of Tooling

manor tool iso 9001:2015 quality assurance manager

Manor’s pledge to industry-leading quality begins even before the work does. Our engineers and quality inspectors work closely with our tooling and development experts to guarantee excellence from the start. We closely monitor every step of the manufacturing process to ensure that products not only meet but exceed the most stringent standards. We’re constantly striving to improve processes, keeping customers’ satisfaction at the forefront of everything we do. Earning the prestigious ISO 9001:2015 certification is just another way to show our commitment to superior quality.

“Achieving ISO 9001:2015 certification for Manor Tool was a team effort, and the process went smoothly thanks to the hard work and dedication of everyone involved. I worked together with all of our different departments, including sales, purchasing, production, inspection, and tool room in order to update our procedures to incorporate risk assessments. By continuously assessing the risk of taking on a large project and the demand associated with that, we can continue to help our customers meet their goals,” said Lucy Lopez, quality assurance manager for Manor Tool.

 

Download a copy of our ISO 9001:2015 certification.

 

Understanding the ISO 9000 Family of Certifications

The ISO 9000 family of certifications was first published in 1987 by the International Organization for Standardization (ISO), laying out the basic principles of quality management systems. Put simply, this family of certifications provides critical tools and guidance for companies and organizations that want to ensure quality standards are being met.

The ISO 9000 series is based on seven fundamentals:

  1. Customer focus
  2. Leadership
  3. Engagement of people
  4. Process approach
  5. Improvement
  6. Evidence-based decision making
  7. Relationship management

The layout is similar to the previous ISO 9001:2008 standard, following the “plan, do, check, act” method, but the new ISO 9001 certification places more emphasis on risk-based thinking. The general purpose of these quality objectives is to assess company adherence to the requirements, facilitate effective deployment of necessary initiatives, and improve quality management systems overall.

ISO 9001:2015 requires companies to document any other procedures required for compliance, and issue and communicate a documented quality policy, a quality management system scope, and key quality objectives. Organizations certified to the ISO 9001:2008 standard have a three-year period to transition to ISO 9001:2015. That transition period ends in September 2018. A new version of ISO 9001 is released about every seven years.

 

Benefits of the ISO 9001:2015 Certification

ISO 9001:2015 certification is important for a number of reasons. Though the certification isn’t law, it’s the world’s most popular standard for quality management systems. Earning the certification reflects a high level of professionalism and shows that a company’s products and services are of a consistent quality.

ISO 9001:2015 certification also illustrates that a company’s offerings meet customers’ unique requirements. Plus, abiding by these guidelines can allow for streamlined business processes as they are continuously improved upon, saving money and time for both Manor and their customers.

Certificates such as ISO 9001: 2015 are invaluable tools in the industrial sphere, helping companies provide better quality and higher service while offering customers ultimate peace of mind. As Lopez said, “A customer will always want to choose a supplier that is proactive about achieving this certification and has the appropriate procedures in place.”

 

Learn More

Visit our Quality Assurance Department page to download a copy of our ISO 9001:2015 certification for your records.

 

 

 

Progressive Die Stamping: Then and Now

Metal components are used in a huge range of day-to-day applications, from smartphones and computers to cars and heavy machinery. Tools, equipment, appliances — and, more broadly speaking, our homes and workplaces — all depend on metal parts.

The emergence of metalworking was a pivotal step in the advancement of modern industry, and the field continues to break new boundaries every day. Our increasingly lightweight and responsive digital technologies, for instance, depend on various precision metal parts.

 

Progressive Die Stamping 101

Metal stamping machines are used to turn raw sheet metal into finished, three-dimensional parts. Allowing for the production of reliably strong, precise, quick-to-produce, durable, and efficient components, this versatile process is becoming more and more common in today’s manufacturing world. Favored for its overall efficiency and dependability, stamping can be used to create a huge range of metal components.

Progressive die stamping takes basic metal stamping technology to a highly detailed level, utilizing multiple work processes to perform different operations on a single part. This type of operation reduces the labor quotient to a negligible amount. Strip or sheet stock is unrolled from a coil and fed through the required manufacturing steps — such as forming, drawing, embossing, notching, punching, cutting, and piercing — resulting in a complex finished part. The high efficiency of this tooling process allows for cost-effective, large runs with very precise tolerances.

 

The Metal Stamping Tradition

Modern punches and dies first appeared in a machining guide in 15th-century Germany; during this time, they were used by locksmiths for hinge manufacturing. As technology marched forward, “successive gang cutting” and “follow-on” tooling innovations led to the first progressive stamping die operation, at the dawn of the 20th century.

These initial operations were primarily done in-house; electric motor manufacturers and machinists used the progressive stamping process to create components in high quantities in order to meet the ever-growing demand.

In the 1950s, Michigan saw the birth of what we now recognize as the first progressive die shop. During this time, engineer Ed Stouten founded the Capitol Engineering Co. to alleviate the shortcoming of the single-hit die manufacturing industry. Within 30 years, Stouten had developed the official manual for progressive die manufacturing, which would come to be referenced by designers, engineers, and managers alike. Stouten also began traveling the country giving educational seminars on the process — changing the face of metalworking forever.

 

Metal Stamping and Modern Industry

Sheet metal is used to create parts of all sizes and styles for a wide range of industries, and its versatility continues to expand. State-of-the-art progressive metal stamping machines are used across a huge range of fields and applications, including:

  • Home and specialty appliances
  • Aerospace engineering
  • Automotive, construction, and heavy equipment
  • Computer sciences, technology, and the Internet of Things (IoT)
  • Dentistry, medicine, and medical devices
  • Electrical, sound, and communications equipment
  • Military and defense
  • Manufacturing and industrial facilities
  • Sporting goods and recreation

 

Progressive Die Stamping Services From Manor Tool

At Manor Tool, we’re proud to carry on the metalworking tradition with highly specialized, adaptable, and extremely precise services for customers across diverse industries. We’re committed to constant improvement and innovation in everything we do, and fully embrace the progressive die stamping process to help provide seamless, quality-controlled transitions when projects evolve from short-run tests to high-volume production. We can work with a range of materials — including aluminum, stainless steel, copper, nickel, and brass — in thicknesses of 0.005 inch to 0.500 inch.

In addition to progressive die stamping, we also offer deep drawn stamping capabilities, as well as custom tooling and fabrication services, manufacturing design and engineering services, and various secondary services. To learn more about our advanced stamping press capabilities or discuss your specific needs with an expert, request a quote today.

 

Internal Machining Centers for Tool & Die Production and Maintenance

Manor Tool & Manufacturing believes customers deserve the finest in tool and die manufacturing. We believe it is an integral part of the manufacturing process. Our eight machining centers create the tooling required for production, supporting one of the largest tool rooms in the greater Chicago area.

These internal machining centers provide the control required to meet the demands of production cycles in today’s just-in-time work environment.

Reasons that Internal Machining Centers Help Meet Production Cycles

Consider the following:

  • Lead times and production scheduling. Our in-house machining centers allow us to set and follow your timetable to complete the tooling. Using a secondary source for machining exposes the tool & die company (and the customer) to unplanned delays.
  • Better accuracy. Specific tooling requirements for tooling features such as hole size or if the hole is tapped, countersunk, or reamed are programmed by us right off the geometry and done in a single set up. Conveying the same information to an outsourced supplier of machining requires more communication, increasing the potential for error, added scrap, and more re-working to fix mistakes.
  • Improved productivity. Keeping all machining in-house prevents issues encountered using a secondary source. There is no downtime because of delays caused by transportation time or supply chain bottlenecks. Employees maintain focus on the customer’s deadline because there is no downtime caused by sending the tool out for machining.
  • Maintaining control of the die/tool. There used to be a public service announcement (PSA) that appeared around 10:00 in the evening: “Parents, do you know where your children are?” The PSA implied that children left without supervision might get into trouble. The same implication fits when having your product shipped to a secondary supplier for machining. You may know the tool & die shop, but how well do you know their machining source? Our in-house machining centers eliminate this worry. The bottom line result is the on-time delivery of an accurately made product without the excessive waste associated with outsourced machining.

Manor Tool Machining Centers

Our eight machining centers are housed in two locations:

Manor Tool & Manufacturing headquarters (three machining centers that work primarily on maintaining dies)

  • Okuma 3-axis CNC machining center
  • Feeler
  • VMC Haas VF5

CLL Engineering (five machining centers focus on die production)

  • Quantum CNC machining center
  • 2 – Okuma 3-axis machining centers
  • Haas CNC machining center
  • Haas TL-2 CNC lathe
  • Versatility in the Machining Center

These machines provide the versatility to accommodate large capacity dies, offer high-speed milling and perform standard CNC machining. Each location emphasizes either production or maintenance support.

However, both locations have the flexibility to do the other’s work in order to meet production needs. A complete list of our tool room equipment is available here:

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For more information on our manufacturing processes, or to learn more about Manor’s in-house machining centers, contact your Manor representative today.

Top 7 Advantages of Progressive Die Metal Stamping Your Parts

Your designers are working hard on your next stamped part and you need to identify the best process.  Should you use
progressive die stamping, cellular work station stamping, or
deep drawn stamping?

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  1. SPEED, SPEED, SPEED! – Progressive die metal stamping is based on the continuous feed of material through the different die stations of a tool.  The nature of the process allows you to create more parts in a shorter period of time when compared with traditional fabrication or machining.  For high volume parts, progressive stamping provides the lowest cycle times per part.
  2. Less Scrap MaterialProgressive stamping is a metalworking method that can encompass punching, coining, bending and several other ways of modifying metal to produce your desired end part shape. The vast majority of material is used, hence, less scrap is produced. Progressive Die Metal Stamping may provide the most cost effective material option for manufacturing your parts.
  3. Quicker Setup – When compared to traditional fabrication or machining, the setup time may be much less for the progressive stamping process. What is achieved in multiple Setups and processes during traditional fabrication and machining, may be performed in one operation if Progressive Die Stamping is utilized. This reduction in Setup and processing will result in a more cost effective piece part.
  4. Create More Geometries with a Single Process – Progressive Die Metal Stamping allows you to create parts with many geometries within a single tool. This video shows a single part progressing through a die. All required geometries of the part are achieved in one Progressive Die operation.
  5. Longer Runs – The continuous material feed used in the progressive die stamping process allows for long runs.   Longer runs between material changes and tooling adjustments mean your parts can be produced in a much shorter time.
  6. High Repeatability – The hard tooling die designs allow for high volume runs without die degradation.  This means that part quality remains high and there are fewer failed parts.
  7. Lower Cost per Part – All of the factors above contribute to reducing the overall cost of your part.  Using progressive die stamping allows you to create robust parts in the most cost effective and expeditious manner.  We look forward to helping you save money on your next project!

 

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Finite Element Analysis (FEA) Offers Problem-Free Production In Component Manufacturing

In component manufacturing and metal stamping, sometimes there are complex geometries in projects, and these complexities offer an infinite number of variables that could negatively impact quality control. For most component manufacturing or metal stamping projects, it makes sense to take advantage of the benefits of performing a Finite Element Analysis (FEA) to ensure problem-free production and positive end results. FEA offers you peace-of-mind by ensuring that your designed component can be manufactured at a production basis, at a point where you can make adjustments, if necessary.

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At Manor Tool & Manufacturing, we’re experienced at conducting FEA, and, with our clients, we’ve witnessed the benefits of FEA first-hand.

Here’s how FEA works: Using FEA software, we turn your product design geometry (the final part design) into tooling surfaces and use it in simulation to engineer a successful forming process in the “virtual world” – at a place and a point where design imperfections can be caught and fixed without negatively impacting tooling, production or your business’ bottom line.

Through our extensive engineering experience and FEA capabilities, Manor offers our clients the know-how and assistance required to help them decrease production costs, save time on their projects, and deliver problem-free production, no matter how complex the design specs might be.

On your next component assembly project, we can help you achieve these benefits – and give you confidence in the final results.

Work with Manor to get innovative component manufacturing solutions that deliver efficient, cost-effective, progressive die-stamped products. Contact us to learn more about our capabilities and to discuss Finite Element Analysis in more detail. Or visit our portfolio gallery and read one of our customer’s success stories using FEA to maximize the effectiveness of the die-stamping process. We look forward to working with you!

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