Productivity Improvement in Slot Piercing Press Tool
Customer required 32 precision slots on both sides of an aluminium extruded channel. The existing manufacturing process involved punching one slot per stroke. First, all 32 slots were punched on one side, then the component was repositioned and the same operation was repeated on the opposite side. Due to intense market competition, the customer demanded a price reduction while maintaining quality standards.
Problem Statement
The original process resulted in:
High cycle time
Increased labour involvement
Repeated component handling
Orientation mismatch between slots on opposite sides
Higher cost per component
To retain the order, a productivity and cost improvement need to be considered
Objective
Reduce production cycle time
Minimize labour and handling
Improve slot alignment accuracy
Achieve cost reduction
Maintain customer satisfaction
Solution Implemented
A redesigned multi-slot piercing press tool was developed with the following improvements:
4 slots punched per stroke
2 slots simultaneously on each side
Common guiding and clamping system
Improved fixture rigidity
Optimized punch and die alignment
This enabled simultaneous punching on both sides, eliminating repositioning errors and reducing process time significantly.
Business Impact
4× productivity improvement
75% reduction in cycle time
Reduced labour cost
Improved slot orientation consistency
Achieved competitive pricing
Successfully retained customer order
Lean Manufacturing Perspective
This project demonstrates:
Waste reduction (motion, time, rework)
Cycle time optimization
Process improvement (Kaizen approach)
Value addition without increasing manpower
Conclusion
· By redesigning the slot piercing press tool to punch four slots simultaneously, the company transformed a high-cost, time-consuming process into an efficient and quality-controlled operation.
· This project demonstrates effective application of lean manufacturing principles inspired by the production philosophy of Toyota Motor Corporation, focusing on waste reduction, process optimization, and value enhancement.
· The improvement not only reduced cost but also strengthened the company's competitive position in the market.
