National Institute of Standards and Technology (NIST) Advanced Manufacturing Technology Consortia (AMTech) Program Award Number: 70NANB14H056 Development of Roadmap and Consortium for Innovation in Sheet Metal Forming Challenge Code Tier 1 Project Titles 1.1 Roadmap of Stamping Supplier Training Needs 1.4 Development of Sheet Metal Manufacturing Training Courses 2.3 Plasticity and Fracture Prediction of Metal Sheets Under Nonlinear Loading 3.2 Effects of Residual Stress on Springback and Part Performance 2.2 Prediction of Trimmed Edge Stretching Performance Code Tier 2 Project Titles 3.4 Closed-Loop Control of Deep Drawing Process Using Servo-Controlled Press 2.5 Plane Stress Fracture Prediction for Aluminum and High Strength Steel Sheets 3.5 Method of Manufacturing Ultra-High Strength Steel Sheet Part

Roadmap of Stamping Supplier Training Needs National Institute of Standards and Technology (NIST) Advanced Manufacturing Technology Consortia (AMTech) Program Award Number: 70NANB14H056 UNH - 28 October 2016 Sheet Metal Forming

1.1 Roadmap of Stamping Supplier Training Needs Project Description: Determine OEM and Supplier outlook on the state of Sheet Metal Forming “human capital” capabilities We are proposing a survey of a representative sample of end users, their tiered stamping suppliers, and their suppliers of sheet metal about their perceived deficiencies as well as those of their supply base as it relates to the skills of their workforce. These results will be summarized and used to aid in the creation a training and development roadmap. UNH - 28 October 2016 Sheet Metal Forming

1.1 Roadmap of Stamping Supplier Training Needs Project Rationale: Millions of dollars are spent on sheet metal forming R&D It is wasted if the implications of the results do not make it to the shop floor Sheet metal forming has used “rules of thumb” that began between the late nineteenth and mid twentieth century. These “rules” are convenient and easy. There is, however, little or no evidence that they are useful and efficient with advanced materials. OEM users of advanced metals typically has direct access to the manufacturers of advanced metals, but the supply base does not always have this luxury. However, most metal stamping is done by the supply base. Without knowing the nuances about these advanced materials, the supply base is left to learn “on-the-fly” and use the outdated Rules of Thumb. UNH - 28 October 2016 Sheet Metal Forming

1.1 Roadmap of Stamping Supplier Training Needs Survey Objective Determine Supplier and Customer Issues Skills Technology Work Habits The recent development of new steels and migration toward “alternative” metals create new challenges for metalforming employees. When employees lack sufficient knowledge of the fundamentals and advancements in materials and technologies, product lead times become extended, scrap rates from forming failures increase, inappropriate materials may be used for the component's application, and investment in necessary forming technologies may prove inadequate. Building a solid understanding about material properties and behaviors, along with advances and research in forming technologies will improve results from forming simulation, reduce die tryout iterations, reduce stamping failures, and better prepare stamping organizations for changes in the industry. With this survey, we are proposing to measure the opinions of suppliers and customers of stamped components about the talent, skill, technical awareness, and work habits of experienced and new industry employees. UNH - 28 October 2016 Sheet Metal Forming

1.1 Roadmap of Stamping Supplier Training Needs Plan and Develop a Quantitative Survey Select Consultant Define Question Topics Survey Interpret Designing and executing a meaningful survey requires understanding of the industry and survey design and execution. Our proposed plan includes the following major activities: Select a trusted consultant to design the survey. Define the breadth and depth of the survey topics to ensure that we are able to draw accurate and meaningful conclusions. Define necessary wording to assure survey recipients that all shared information is confidential. Prepare survey. Develop a mailing list of appropriate executives and influencers within organizations involved in the sheet metal forming industry to receive the survey. These should include representatives from metal producers, metal service centers, end-use manufacturers, and tiered stamping companies. Engage consultant to develop appropriate processes to obtain a statistically meaningful response rate. Deliver survey request. Interpret results. Publish paper explaining results and appropriate actions to assist stamping organizations. UNH - 28 October 2016 Sheet Metal Forming

1.1 Roadmap of Stamping Supplier Training Needs Written details of the proposal follow on the next 3 pages UNH - 28 October 2016 Sheet Metal Forming

1.1 Roadmap of Stamping Supplier Training Needs Objective: Measure the opinions of suppliers and customers of stamped components and record the industry's opinions about the talent, skill, technical awareness, and work habits of experienced and new industry employees. Survey a representative sample of metal suppliers and OEMs about their perceived deficiencies as well as those of their supply base OEMs include steel/aluminum companies and end users of advanced metals Supply base includes metal service centers and Tier stamping companies Summarize the results to aid in the creation a training and development roadmap. Technical Benefits: The recent development of new steels and migration toward “alternative” metals create new challenges for metal forming employees. When employees lack sufficient knowledge of the fundamentals and advancements in materials and technologies, product lead times become extended, scrap rates from forming failures increase, inappropriate materials may be used for the component's application, and investment in necessary forming technologies may prove inadequate. Building a solid understanding about material properties and behaviors, along with advances and research in forming technologies will improve results from forming simulation, reduce die tryout iterations, reduce stamping failures, and better prepare stamping organizations for changes in the industry. UNH - 28 October 2016 Sheet Metal Forming

1.1 Roadmap of Stamping Supplier Training Needs Technical and Non-Technical Obstacles: Sheet metal forming has used “rules of thumb” that began between the late nineteenth and mid twentieth century. These “rules” are convenient and easy. There is, however, little or no evidence that they are useful and efficient with advanced materials. OEM users of advanced metals typically has direct access to the manufacturers of advanced metals, but the supply base does not always have this luxury. However, most metal stamping is done by the supply base. Without knowing the nuances about these advanced materials, the supply base is left to learn “on-the-fly” and use the outdated Rules of Thumb. At many companies, employee development is not a managed activity. Human resource departments focus primarily on compliance and administration while operations managers focus mostly on current issues. As a result, supporting a real understanding of the science and technologies of sheet metal forming goes unaddressed. UNH - 28 October 2016 Sheet Metal Forming

1.1 Roadmap of Stamping Supplier Training Needs Path to Implementation: Select a trusted consultant to design the survey. Define the breadth and depth of the survey topics to ensure accurate and meaningful conclusions can be drawn. Define necessary wording to assure survey recipients that all shared information is confidential. Prepare survey. Develop a mailing list of appropriate executives and influencers within organizations involved in the sheet metal forming industry to receive the survey. These should include representatives from metal producers, metal service centers, end-use manufacturers, and tiered stamping companies. Engage consultant to develop appropriate processes to obtain a statistically meaningful response rate. Deliver survey request. Interpret results. Publish paper explaining results and appropriate actions to assist stamping organizations. UNH - 28 October 2016 Sheet Metal Forming

1.1 Roadmap of Stamping Supplier Training Needs Discussion: Anything missing for active industry support? Estimated benefits realistic & complete? Technical and non-technical obstacles complete or over reaching? Alternative implementation paths or better approaches? Conflicts with intellectual property or trade secrets? UNH - 28 October 2016 Sheet Metal Forming