PAY BACK CALCULATION / RETURN ON INVESTMENT

Let us calculate pay back / return on investment on Aditron quick die change in three steps

  1. The normal average time taken each die change say from 60 minutes to 240 minutes—-your time change each die / mould you understand
  2. Your each press can make strokes per minute—— so much
  3. You save per stroke say 50 p to rs five per stroke–depending upon your end product
  4. The industry average per person cost say rs 4 to 10 lakhs per year
  5. If you save 20 –90 percent time wise for each die change that is your ROI–pay back can be with in 50–250 die changes– few weeks or few months

Other Benefits

Reasons to consider aditron quick die change towards goal of SMED / JIT solutions

  • Increased production— improved margins– improved net profit
  • You can plan for shorter batch production
  • Your die change is not depending upon big team reduces man power– man power can be better utilized for more productive work
  • You can use your fork lifts –over head cranes- for other more productive use
  • A¬†dedicated facility for quick die change in three steps– — lifting——shifting- ——storing—- only push pull required
  • Better / faster response to your customers–as die change is faster and simpler
  • Aditron quick die change system is maintenance free– you need only push or pull—- other equipment s not required

Trying to give further details– explaining each and every costs / factors you may consider— although you know it better

Let us further calculate the pay back time — return on investment — which is a must for any proposition

The pay back may be direct or indirect depending upon your thought process understanding reqirements limitations

A user is the best to reach a figure and the process of calculating the costs — we are sharing our thoughts for pay back –ROI

For quick die change system– towards goal of smed–jit solutions–in three steps

1- PL observe the present process noting time taken in each to reach cost of each process

A– Step no one— die lifting from t slots-u slots form the bed / bolster / from the bed base

Pl record / and note the time taken in lifting the dies / moulds from the bed / bolster and number of persons involved each person is a cost to the company–the effort and force needed to lift the die– if you are using any other eqipment say a fork lift / or overhead crane— on per hour or per cycle bases estimate the cost no fixed rulle apply

More space is reqired to handle dies with fork lifts– over head crane as compared to a trolley

Do note the time taken by the fork lift to reach from his earlier location to the press– the cost to include driver salary– cost of diesel etc etc
Although you have already invested in the fork lift– over head crane but its running and maintenance is a cost–in few cases the user is not very keen as he need to provide larger space of movement of fork lift or over head crane / he needs to move shift other eqipments

It is observed that in most of the industries the die change process gets delayed as the driver is pre accupied in some other work either he delays in coming to press or he is waiting for the die change in both the cases, the productivity and cost gets effected as it get increased osts resulting in reduced production

We understand from a user that they had over five fork lifts- and most of the time the driver needs say 20–90 mints in reaching the location / the press or he is waiting for die change- in both cases the cost and time matters–as cost / efforts get increased– to follow uip each step not easy

It was noticed that die change was not possible as the driver of fork lift not available– but it happens in limited no of times not every where

If the die lifting is manual the cost of resources – man power say 4–6 persons is very very high and man power is always limited– since it is show of strength the workers are not keen to do the efforts– it involves a certain level of risk / safety for the people and the expensive die / mould also get effected— the bed base needs better care

If you invest in Aditron die lifters roller arms to lift the dies upto 10 000 kgs— ten tons the die lifting time will be reduced by 20–90 percent time wise

As you need to just activate the die lifting arms throuigh a hand lever valve–activation mechsanicallyor pneumatcallyor hydraulic–depends upon die weight–size— and t slot size– you may need one pairs to four pairs

Although the clamping and declamping time remains the same– cost not changed–time not saved in clamping -declamping

Our experience no 1–

To our shock and surprise one of most reputed and very very large metal stamping industrial unit using 10–20 year old fork lifts– seven nos we have seen storing dies in 20 tiers one above the other not in rack- directly one die over the other die — damaging the die and lifting one by one to change,— die change time few hours each day planning almost 3–5 days– we reconfirm few hours and few days for each job

if you change heavy die s by pushing or pulling directly on the bed / bolster the bolster / the press bed- get damaged –also reducing the life of die resulting in reworking –rejection of components and other costs- your experience is good enough to take a call

we can share with you many many stories of big and small quality minded users and production oriented units— but die change process almost similar only to a good jugar– without any proper method reasons god knows——– without roller lifting arms–

if you already have roller lifting arms for the t slots — good ————————-move to step no 2–

many many times a customer wish to have a dedicated facilities so that die change is done without ifs and buts– saves time without hick ups

As per our knowledge the pay back will be with in 50–250 die/ mould changes– say with in 6–18 months– may be shorter– / longer depends upon the no of die changes you do day in day out —

As a user you can understand process better to see actual time taken for a die change in week or in a month as some time it will be fast and some time really delayed average time will the limitation for a buyer to reach a figure

We understand if you reduce your die change time wise say by 20-90 percent , resulting in increased production , reduced efforts ,better safety- lesser use of man power– without using any other equipment– just pushing pr puling dies which is floating on Aditron roller arms –pay back will be very very short– worth the investment

-Step 2

Once die is lifted you need to place it on a roller top trolleys –the trolley may be hydraulic hand pump operated– or mechanical with automatic interlocking facilities- a safety feature– the trolley will not move during die exchange as locked with the press

It is better to have two trolleys one for loading the die inside the press the other for taking the die coming out of the press- otherwise the production is stopped for that much longer time– which can be 60 minutes to few hours depending upon your process of storage

Once the die comes out you can take it to the storage rack by over head crane– or a fork lift– the over head crane or fork lift will do this process when they are free not accupied in any other work– may not be time bound– no body is waiting dueto any reason

Or you can push the trolley manually to the die storage rack for dies with weight in 2500kgs— 5000 kgs by one or two persons

Experience story no–2–

We had a customer having really expensive dies worth few lakhs each die– total dies ten nos— he inform us for each stroke he saves almost seventy five paise only perstroke — the press cost almost 40–75 lakhs—- it was decided by the customer he will store all the dies directly on mechanical trollies / not in the rack so that die handling time is minimum – although he had extra forklifts– but due to safety reasons– savings in die change time and increasing production it is better to store dies on trolleys– if space permits– and to reach your goal of SMED / JIT solutions

Step-3– for die/ mould storage

You must store dies / moulds/ jigs fixtures in racks– not on the ground— not one above the other—– you may fabricate racks yourself

It is better to store dies in one/ two / three tier roller type racks so that dies can be pulled or pushed easily if the weight is with in 10000 kgs– you may use our roller blocks or roller rails in your existing racks– and other handling equipments try to roll– than lift — roll as much as possible

If practical if number of dies not very large you may consider storing your dies and moulds in one tier racks– troleys matching bolster height matching your press bed height — so that height adjustment is not reqired at the storage or die exchange resulting in considerable increase in production / savings of time / efforts/ safety etc during die loading —unloading at the press / or at the storage a every step counts

Pl study your application–process your thoughts will be better than ours

It is surprised that most of the press shops are happily loosing money for so many years during each die exchange some body need to have initiative
To implement any better method for die exchange – die/ mould lifting – die shifting – die storage let us start in a small way if satisfied implement for all other presses in near future