Stamping Press Operator & Die Setter Training for Coil- and Manually Fed Presses

• Increase Productivity • Assure Safety

• Improve Part Quality • Reduce Scrap & Rework

PMA’s training systems designed bymetal stampers to:

• Foster workplace safety and productivity improvements

• Minimize downtime and interruptions to the work schedule

• Assure proper documentation for personnel and safetyrecord keeping

• Meet training requirements for ISO and QS qualitysystems registration

Supporting the metal stamping, fabricating and forming industries

Employee training is an investment whichwill pay dividends in your company’s future.

MaterialsA video is the basis for learning each lesson. The system is supported bytwo manuals—one for trainees and the other for trainers. The trainee manualincludes a description of the system, learning objectives, performance testsand work sheets to be completed after viewing each lesson.

The trainer manual provides proven guidelines for implementing the programand monitoring effectiveness, including instructions for first-line supervisorsto administer performance tests, grade for correct answers and track theprogress of individual trainees. Job aids and certificates of completion arealso included.

Learning Method• Focus responsibility for learning on the employee

• Encourage trainees to work at a comfortable pace for maximum compre-hension

• Allow the flexibility to customize the system to company needs

The training process includes watching a video as many times as needed tolearn the material in the lesson, and then completing a worksheet to demon-strate comprehension. The trainee then uses production equipment to gainhands-on experience in successfully applying the concepts learned from thevideo. A series of performance tests are administered at the press to assurecompetency before moving on to the next lesson.

The entire system consists of nearly 51⁄2 hoursof video and more than 600 pages of written support material.

Our coil-fed press trainingsystem is available inSpanish. Same greatfeatures and learning foryour Spanish speakingstampers.

The Modular FormatVideos — The system consists of 26 lessons; the basic learning tool is a video for each lesson. Videos vary in length from 8 to 19 minutes. Special effects andgraphics are used throughout to stress key points. Nearly six hours of video andover 600 pages of text form a total training package.

The modular format allows your company to purchase the program customized toyour production processes without duplication of lessons. You may purchase the:• Coil Fed Press System (represented by this <coil>symbol) consisting of 23 lessons

• Manually Fed Press System (represented by this <hand>symbol) consisting of15 lessons

• Both Coil Fed and Manually Fed Press Systems(represented by both <coil & hand> symbols) consisting of 26 lessons.

Refer to the Lesson Outline to determine the lessons included in each system.

Manuals — The system is supported by two Manuals, one for Trainees and one forTrainers.

The Trainee Manual provides the trainee with a description of the entire system andthe View/ReView process. For each lesson learning objectives are defined, performance tests are described, and worksheets are provided for completion afterviewing each videotape.

The Trainer Manual has sections for Managers, Supervisors, and Graders. TheManager Section provides the manager responsible for employee training with adescription of the View/ReView process, guidelines for implementing the trainingsystem, and suggestions for monitoring its effectiveness. The Supervisor Sectionincludes performance tests for each lesson and provides the first line supervisorwith instructions for administering the performance tests and tips for overall imple-mentation of the system. The Grader Section includes answers to the written work-sheets for each lesson and forms to track each trainee’s progress.

Written Job Aids — The system includes written and illustrated job aids to support the videos. Many companies develop their own job aids for processesunique to their operations.

Certificates of Participation— You will receive a packet of 10 Certificates ofParticipation to be awarded to trainees at the successful completion of their training.

View/ReViewThis process starts with the trainee viewing a video lesson as many times as need-ed to feel comfortable with the material. After viewing, the trainee completes aworksheet to demonstrate that key information has been learned. This is necessarybefore moving to the next step. The trainee is then exposed to production equip-ment during the practice step. This hands-on experience takes place under closesupervision and confirms that the trainee is capable of successfully applying con-cepts learned in the video. As a final competency check, the trainee must com-plete a series of performance tests on a production machine. The trainee moves onto the next lesson only after demonstrating learning through the worksheets andperformance tests.

Lesson OutlinesThe following lesson outlines indicate primary tasks covered in each lesson.The instruction system relies on video lessons, written worksheets, in-plantpractice and review sessions, and View/ReView evaluation of employees.This training system is used to train an employee to perform the basic tasksrequired of a stamping press operator and die setter. It can be modularizedinto one of three systems.

The entire 26 lesson system covers both Coil and Manually Fed Presses.

The 23 lessons included in the Coil Fed Press Operator and Die SetterTraining System are identified with the <coil>symbol in the outline below andthroughout the videos and manuals.

The 15 lessons included in the Manually Fed Press Operator and Die SetterTraining System are identified with the <hand>symbol in the outline belowand throughout the videos and manuals.

(When both symbols are used with a lesson, that lesson is included in bothtraining systems.)

KEY

Applies to Manually Fed Press

Applies to Coil Fed Press

Applies to Both

Lesson 1 — INTRODUCTION TO THESTAMPING PRESS

1. Overview of stamping and the various types of presses2. Components of Straight Side and OBI presses and their

function3. Definition of key terms such as strip, coil stock, blanks,

piece parts, slugs, scrap, etc.4. Operation of a press and the sequence in the stroke of

a press5. Differences between full revolution clutch and part revo-lution clutch presses and their effect on operator safety

Lesson 2 — DIE COMPONENTS ANDTHEIR FUNCTION

1. Dies (single station, progressive, blanking, transfer) andcommon die parts and their function

2. Punches — cutting, forming, combination3. Common components of a die assembly and their func-

tion.

Lesson 3 — UNCOILER, STRAIGHTENER, & FEEDCOMPONENTS AND THEIR FUNCTION

1. Additional functions of coil fed press lines — uncoil /straighten / feed / re-reel

2. Overview of additional components of coil fed stampingline, showing several types of uncoilers, re-reelers,straighteners and feeds

3. Uncoilers — review of major parts of reels and cradles,components and controls used by the operator inreloading a coil in an existing set up

4. Straightener — coil set, review of parts, their purposeand how they work

5. Loop control devices — various types available andtheir function

6. Feeds — Roll feeds and Air Feeds, their purpose andhow they work

7. Servo-Driven roll feeds — typical control functions

Lesson 4 — PROPER DRESS &SAFETY DEVICES

1. Explain Point of Operation, importance of safety andwarning signs

2. Dress for safety — protective clothing, glasses, shoes,hearing protection, jewelry

3. Common safeguarding devices and how they work4. Safety tongs and when to use them5. Safe Distance

Lesson 5 — BASIC OPERATOR CONTROLSAND LOCKOUT/TAGOUT

1. Identification of press controls used by the operator andtheir purpose

2. Common modes of operation — when and how to initi-ate each mode

3. Actions necessary to initiate the continuous mode ofoperation

4. Four components that will stop slide motion5. Lockout/Tagout — what it is, when it’s used and its

importance to employee safety.

Lesson 6 — SAFE OPERATION ON THEMANUALLY FED PRESS

1. Lockout/Tagout awareness2. Clean and organize work area, eliminating any safety

hazards3. Maintenance checklist, inspection of press and compo-

nents prior to operation4. Proper use of safety devices including pullbacks5. Lubrication and placement of blank in die6. Start and operate the press.7. Identify common “mis-hit” piece parts and explain their

possible causes.

Lesson 7 — SAFE OPERATION ONTHE COIL FED PRESS

1. Lockout/Tagout awareness2. Clean and organize work area, eliminating any safety

hazards3. Maintenance checklist, inspection of press and compo-

nents prior to operation4. Inspect and power up all safety devices and auxiliary

equipment5. Starting and operating the press6. Explanation of top-dead-center and bottom-dead-center7. Identify controls used in various modes of operation

and their function8. Stop signals and their effect on full and part-revolution

presses

Lesson 8 — BASIC OPERATIONSPERFORMED ON THE DIE

1. Three major die operations — cutting, forming anddrawing.

2. Identify from piece part features the basic types ofshearing operations

3. Identify from piece part features the basic types offorming operations.

4. Identify drawn piece part features and name the vari-ous types or stages of draw pieces.

Lesson 9 — COIL HANDLING AND ADVERSE COIL &MATERIAL CONDITIONS

1. Safe practices when handling and lifting coils2. Coil handling equipment — lifting devices (crane, hoist,

forklift), lifting tools (slings, c-hooks, coil grabs, coillifters), coil tipper/up-ender, coil cars

3. How to identify common adverse coil conditions andtheir effects on production.

4. How to identify common adverse material conditions(excessive coil set, camber, crossbow, coil break, edgewave) and their effects on production

Lesson 10 — OPERATING EXISTING SETUPS ANDTHE IMPORTANCE OF THE SLACK LOOP

1. Initial Coil Fed Press Line setup steps prior to operatortaking over production

2. Operator production duties—primary functions —begin production run, monitor the operation

3. Monitoring press operation to prevent damage to thedie and press, to perform quality checks (check piecepart quality, gaging, SPC), and to service components ofthe press line (scrap/parts bins, lubricant reservoirs,clear conveyors, load new coils)

4. Automatic malfunction detectors and their purposes5. Concept and importance of slack loop in the coil fed

press line6. “No Loop Faults” and their causes7. “Excessive Loop Faults” and their causes8. Loop control devices/safety issues associated with

them

Lesson 11 — UNCOILING AND STRAIGHTENINGPROCEDURES

1. Loading a stock reel, cradle and straightener2. Coil set — what it is and why it must usually be removed3. Locations for straighteners4. Common straightener controls used in reloading coils5. Common straightener components and their function

Lesson 12 — LOADING COILS INTOEXISTING SETUPS

1. Lockout/Tagout awareness2. Remove leftover strip (skeleton) or butt-weld to new

coil stock3. Loading the stock reel, cradle, and straightener 4. Loading stock into the feed5. “Walking or inching the strip” through the die — man-

ually or using inch or jog control

Lesson 13 — INDICATORS OF INCORRECTOPERATION

1. Basic shearing operation, identify the parts of thesheared edge

2. Three stages in a shearing operation3. Common indicators of incorrect shearing, its causes

and required corrective action4. Indicators of worn edges in a die assembly and

required corrective action.5. Indicators of incorrect forming, its causes and required

corrective action.6. Burnishing as an indicator of incorrect operation7. Indicators of damaged, dull, or worn punch and die8. Examples of sharp and dull/worn tooling9. Inspecting finished piece parts

Lesson 14 — DIMENSIONAL MEASURING &GAGING PIECE PARTS / SPC

1. Using micrometers and calipers — the basics2. Measuring parts using electronic indicators3. Gage tickets and gage masters — finding tolerance

limits4. Mechanical dial indicators — balanced dials and con-

tinuous dials5. Installing a piece part in a fixture gage.6. Measuring a piece part with a dial indicator, electronic

indicator, or micrometer head mounted on a fixturegage.

7. Overview of Statistical Process Control and the opera-tor’s role in it

Lesson 15 — ATTRIBUTE GAGINGOF PIECE PARTS

1. Checking parts on jigs and fixtures,2. Installing a piece part in a fixture gage3. Gage tickets4. How to use common gauging devices — plug gages,

gap gages, bar gages, window gages, GO/NO GO pingages, window gages, “specialty” gages

Lesson 16 — SETUP CONTROLS

1. Lockout/Tagout awareness2. Determining the size and adjustment limits of the pressand other basic preparations

3. Identify, name, and state the purpose for each of thecontrols used during setup.

4. Electrically interlocked safety blocks and their function

Lesson 17 — REMOVING THE DIE ASSEMBLY& DIE CLAMP SELECTION

1. Lockout/Tagout awareness2. “Last Good Part to First Good Part” die change efficiency3. Disconnecting/removing auxiliary equipment from the

die area4. Removal of safety block from holder and placement

under press slide5. Adjusting knockout bar and striker mechanism clear of

the die area to prevent damage6. Releasing die cushion pressure7. Unclamping the die from the previous setup8. Removing pressure pins 9. Removing die from the press10. Selecting appropriate clamping components for the

next die assembly11. Proper installation of various clamping components

Lesson 18 — INSTALLING THE DIE PT. 1 —LOADING THE DIE & THE SHUT HEIGHTADJUSTMENT MECHANISM

1. Lockout/Tagout awareness2. “Last Good Part to First Good Part” die change efficiency 3. Proper placement of safety block under press slide4. Cleaning and smoothing the bolster and press slide5. Selecting and installing pressure pins6. Loading and aligning the new die on the bolster7. Rough adjust the press shut height to avoid bottoming

out at stroke down.8. Shut height adjustment mechanism and function

Lesson 19 — INSTALLING THE DIE PT. 2 —ADJUSTING SHUT HEIGHT/CLAMPDIE/COUNTERBALANCE

1. Lockout/Tagout awareness2. “Last Good Part to First Good Part” die change efficiency3. Adjusting shut height (rough)4. Clamping the die5. Checking stop block clearance and fine adjustment of

shut height6. Lubricating the leader pins 7. Adjusting the knockout bar8. Adjusting the air counterbalance pressure9. Inching through cycle (dry) to check for proper adjust-

ment, die loosening, etc.10. Adjusting the variable speed drive (coil fed)

Lesson 20 — SETTING UP PULLBACKSAFETY DEVICES

1. “Poisons” brand pullbacks — Components, their func-tion, and procedures for adjusting

2. “Safeguard” brand pullbacks — Procedures for adjust-ing the cable length and travel (“dwell”)

3. Inspecting pullbacks

Lesson 21 — TRIAL STAMPING THE FIRST PIECEPART – MANUALLY FED PRESS

1. Trial stamping the first piece part and adjusting thepress to produce an acceptable piece part.

2. Arranging and installing the parts bins and conveyors.3. Installing and adjusting piece part ejection devices.4. Positioning point-of-operation safeguarding5. Reviewing the setup with operator

Lesson 22 — AIR-OPERATED BRIDGE GRIP FEEDS

1. Identifying the basic feed components and the basicadjustments of feed timing, feed length and feed speed

3. Mechanical and electro-pneumatic methods for feedtiming

4. Setting the feed timing, length, and speed5. Loading stock into the feed and the function of pilot pin

release systems

Lesson 23 — AIR-OPERATED OPEN THROAT GRIPFEEDS (with pull through straighteners)

1. Basic components and explanation of basic functions tostraighten and feed stock

3. Adjusting the (rough) height of the feed in both “cabinetmounted” and “press mounted” OTG feeds

4. Adjusting the timing of the feed cycle and pilot pinsrelease (electro-mechanical system)

5. Rough adjusting the feed length, feed advance speedand feed gripper return speed

6. Loading stock into the feed

Lesson 24 — MECHANICAL ROLL FEEDS–PART 1

1. Basic principles of Servo-drive electronic roll feed2. Basic components and operation of mechanical, press-

driven roll feeds — eccentric driven and cam driven3. Description of first three major steps in setting up

Mechanical Roll Feeds — basics of eccentric driven rollfeeds, feed height and feed length, and stock guide width

Lesson 25 — MECHANICAL ROLL FEEDS–PART 2

1. Description of steps four through six in setting upMechanical Roll Feeds — feed timing, pilot release,and feed roll pressure and other adjustments

Lesson 26 — TRIAL STAMPING 1ST PARTSON COIL FED PRESS

1. Final check of coil line — press, die, feed, malfunctiondetectors, auxiliary equipment, safety devices

2. Performing safety checks to make sure the die area isclear of tools, etc.

3. Checking control positions and slack loop content4. Positioning and turning on part/scrap conveyors, lubri-

cation systems5. Advancing the stock to the die starting position and

“walking it through” the die and adjusting the pilot pinrelease timing

6. Visually comparing first few production parts to anapproved sample part and obtaining part approval

7. Connecting, adjusting and activating malfunction detec-tors, auxiliary equipment (conveyors, chutes, part bins,scrap bins, automatic counting devices) and “point ofoperation safeguarding”

8. Obtaining final approval for production from supervisor9. Reviewing the setup with operator and beginning pro-

duction

Other PMA TrainingSystems for Employees

•Dimensional Variations in Flat RolledMetals

• Economics…Making Dollars & Sense• Lockout for Safety, Lockout for You!• Metal Spinning Machine Operator• Press Brake Operator• Safety FirstContact PMA or visit our web site at www.pma.org foradditional information on these and other training toolsavailable from PMA.

www.pma.org

4 easy ways to order Stamping Press Operator & Die Setter Training SystemMail to: Precision Metalforming Association Fax: 216-901-9190

c/o Publications6363 Oak Tree Blvd. Phone: 216-901-8800Independence, OH 44131-2500

Internet: www.pma.org/marketplace

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For orders shipped within the continental United States,Canada and Mexico, please allow 1-4 weeks for delivery. International customers please allow 6-8 weeks for delivery.Your credit card will not be charged until items are shipped.Please note: prices are subject to change without notice.

Shipping & Handling Charges are FREE for PMA membersNonmembers please add:Order Amount U.S. Canada/MexicoUp to $99 $6.00 $15.00$100 - $250 $8.50 $17.50$251 & over $15.00 $25.00International charges vary according to destination andweight. To determine your cost before you place an order,contact Publications at PMA headquarters by e-mail,publications@pma.org, fax at 216-901-9190 or by phone(8:00 a.m. to 4:00 p.m. ET) at 216-901-8800.

AGREEMENT AND CONDITIONS OF SALE

1. The Training System has been purchased for the exclusive use of ouremployees, or the employees of subsidiaries or satellite plants.

2. We understand that all materials in the Training System are copyrighted byPMA. Permission to reproduce the written materials is granted by PMA to allpurchasers of the Training System. Permission is not granted to reproduce thevideotape materials. (Replacement tapes are available from the Association incase of damage, loss or theft).

3. We acknowledge that the Training System has been developed to help PMAmembers train their employees, and that the Association has no responsibilityregarding, and does not undertake to instruct our employees regarding, anysafety procedures necessary for the specific machines used in our operations.

4. We agree to defend, indemnify and save harmless the Precision MetalformingAssociation (PMA), its officers, directors, employees and agents orrepresentative against any and all loss, claims of any kind, cost or damage onaccount of any injury to persons or property occurring in/or related to our useof this purchased Training System in our businesses, facilities or operations.

PRODUCT DVD’S QTY MEMBER NONMEMBER TOTAL

COIL AND MANUALLY FED $2,595 EA. $7,795 EA.

COIL FED PRESS $1,995 EA. $5,995 EA.

MANUALLY FED PRESS $995 EA. $2,995 EA.

SPANISH COIL FED PRESS $995 EA. $2,995 EA.

6363 Oak Tree Blvd.Independence, OH 44131216-901-8800Fax 216-901-9190www.pma.org

Stamping Press Operator &Die Setter Training for Coil- and Manually Fed Presses

• Increase Productivity • Assure Safety• Improve Part Quality • Reduce Scrap & Rework

Developed by stampers for use in the metal stamping industry