The discipline of tooling design is fundamental to manufacturing. The cost of manufacturing and of the end product depends heavily upon tool design.
Tool design affects the cost in several ways. First, it determines the tool life, which is how long the tool last before requiring a replacement. Second, it affects the quality of the product, and any cost of poor quality and reworks costs, which adds to the total cost of the final product. Third, tool design can affect the cycle time of the manufacturing process, which enables us to produce more or fewer units in a given time. For these reasons, it is important to understand the fundamentals of tool design.
This article will cover various basic aspects of tooling design.
What is tooling design?
Tooling design is a specialized area of manufacturing engineering which comprises the analysis, planning, design, construction, and application of tools, methods, and procedures necessary to increase manufacturing productivity.
What is a die tool?
In the article: Mold Design Is The Key, An Effective Way To Reduce The Cost Of Die Casting Mold, we defined die is a specialized tool that is used to shape or cut the manufacturing material. The material includes fabric, wood, plastic which are into predetermined shapes. Man-made mass-created products require tools, similar to the shaped die, to be designed in progress specifications in order to start the production process. Externally designed die-cut tools secondary objects will be constructed that have been lead to the failure, following in whole product batches remain waste. The die tool designer should support the manufacturer from the pre-production work to the production process. The tool designers should follow a few things before starting the work, it’s about product blueprints, iron out potential, and design flow. The tool designers will protect the manufacturer in many ways; capital, and additional pains by securing the product is machine-ready before it operates on the press of the product.
The tooling design plays a vital role in all stages of the product manufacturing process. Once the production process is completed without any errors, design for the manufacturer will give the assurance for the quality and productivity of material. Progressive Die Design is one of the best methods of die tool designing. Make sure to use it in different sectors of manufacturing.
Tool Design General Process
The tool designer should follow the below process for manufacturing a product.
- The statement and analysis of the problem
The tool designer can assess the manufacturing product status and they can analyze the problem in the process of manufacturing. The tool designer should give the statement of the product plan to the manufacturer, mentioning the blueprint and detailed structure of the manufacturer expected product.
- Analysis of the manufacturer requirements
The tool designer should design the tool according to the manufacturer expected product requirements. A designer can analyze the structure, feel etc., of the product. The manufacturer main requirement is cost cut and material usage, being in this two limitations the tool should be designed.
- Development of initial ideas and design alternatives
The tool should be designed and that should develop initial ideas for the manufactured products. Tool designer should also design an alternative tool for the same product. The tool may be used or not but for the safe side, designers should prepare a similar kind of tool for any misleads.
- Finalisation of design ideas
The manufacturer finalizes the expected product, the tool designer should conclude the tool designing process based on the manufacturer need. If the designer gets the confidence that the tool reaches the manufacturer’s idea then the tool designing process will be finished.
Important objectives of tool designing in the manufacturing process
- Reducing cost levels
The manufacturing costs will increase the gross profit of the company. Manufacturing expenses, which include materials, employees, and costs of equipment, etc., are used to calculate the expenses of a company. The tool design reduces all over the cost of manufacturing products. It can produce parts of the product with respect to the cost. It reduces the cost of special tooling systems by designing every product effectively.
- Quick deliverables
The company should maintain the good process in the process of manufacturing. For better output manufacturers should maintain good communication with all the people related to product development. By using the tool design, a manufacturer can get the highest production rate in the manufactured product. The manufacturer will also get the product parts as quickly as possible. A manufacturer who have the good understanding of how a product change affects all functional groups.
The quality of the product: The quality is a trust that ensures consumers receive goods free from damages and meet their requirements. The manufacturer main aim is to maintain the good quality of the product. The tooling design is used successfully to deliver the quality product continually with the required precision. The quality of the product increases customers loyalty, it gains repeat business along with new customers from referrals. Maintain or improve manufacturer position in the market. The quality deliverables improve safety and reduce liability risks.
The designing tools are safe in case of utilization, the manufacturer can use it easily. For product development, the manufacturer feels the tool designing is easy to design the product as per the expectations. It is simple for the manufacturer to learn and monitor the process of producing a new product. For a manufacturer, it is easy to navigate the process of developing the product. As a produced person, they don’t want any third party to access the production system.
The tooling design is very much useful for the manufacturers to develop the new products within the given time. There are several kinds of usages like cost-cutting, on-time deliveries, quality of the product etc., Manufacturers usually depend on the employees to develop the product, but they fail to give the output on time because of labor shortage or machine problems etc., But finally the tool designing became a more useful element in the development of the products. Manufacturers feel comfortable in using the tool design, they should reach the customer’s expectations and grab the loyalty in the market.