[WS-Press]

CQI (Continuous Quality Improvement) for Press Operations,

1. Relevant CQI Standards for Press Operations

• CQI-9 (Special Process: Heat Treat System Assessment)

  • While focused on heat treatment, its process-control principles can be adapted for press operations (e.g., temperature, force monitoring).

• CQI-15 (Welding System Assessment)

  • Useful for welded stampings; emphasizes process validation and operator competency.

• CQI-23 (Molding System Assessment)

  • For plastic/composite presses; aligns with press control plans.

• CQI-24 (Casting System Assessment)

  • Relevant for die-casting presses (e.g., aluminum, zinc).

Note: No dedicated CQI standard exists for metal stamping/press operations, but the above can be tailored.

2. Press-Specific Quality Assessment Framework

(Modeled after CQI-11/CQI-9 Structure)

A. Process Control & Monitoring

• Tooling Maintenance: Dies/molds must be inspected, cleaned, and documented.

• Press Parameters: Monitor tonnage, speed, shut height, and alignment (SPC recommended).

• Material Verification: Confirm material grade, thickness, and coating pre-pressing.

B. Equipment & Calibration

• Preventive Maintenance: Scheduled checks for hydraulic systems, clutches, and sensors.

• Calibration: Load cells, pressure gauges, and laser micrometers must be calibrated.

C. Personnel Training

• Operator Certification: Training on press setup, safety, and defect detection (e.g., cracks, wrinkles).

• Die Changeover: SMED (Single-Minute Exchange of Dies) competency.

D. Nonconformance Management

• Root Cause Analysis: Use 5Why/8D for press-related defects (e.g., galling, mis-strokes).

• Containment: Quarantine nonconforming parts and verify corrective actions.

E. Safety & Compliance

• OSHA/ANSI Standards: Guarding, lockout/tagout (LOTO), and noise control.

• Environmental: Scrap/recycling procedures for metal waste.

  
  

3. Press Process Audit Checklist (CQI-Inspired)

Category	Audit Questions	Evidence
Process Control	Are press parameters documented and monitored?	Control plans, SPC charts
Tooling Management	Are dies inspected for wear/damage after each run?	Inspection logs, maintenance records
Material Handling	Is material verified before loading?	COCs, thickness measurement records
Safety	Are safety interlocks functional?	OSHA logs, LOTO procedures

4. Continuous Improvement for Press Operations

• Kaizen: Regular workshops to reduce setup time/scrap.

• Automation: Implement sensors for real-time defect detection.

• Benchmarking: Compare OEE (Overall Equipment Effectiveness) with industry standards.

5. Integration with IATF 16949

• Risk-Based Thinking: Include press risks in PFMEAs.

• Customer-Specific Requirements (CSRs): Follow OEM stamping standards (e.g., Ford’s Stamping Process Standards).

More ..

1. Develop a Press-Specific CQI Checklist using CQI-9/CQI-11 .

2. Adopt IATF 16949 Core Tools (APQP, PPAP, MSA) for press processes.

3. Leverage Digital Tools: Press monitoring software (e.g., Press Dashboard by 4DSPC).

Note a customizable press audit or guidance on press-specific PFMEAs....