1. 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

2. 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

3. 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

4. 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 Without knowing the nuances about these advanced materials, the supply base is left to learn “on-the-fly” and use the outdated Rules of Thumb.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

5. 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

6. 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

7. 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

8. 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

9. 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

10. 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

11. 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

12. 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

13. Development of Sheet Metal Manufacturing Training Courses National Institute of Standards and Technology (NIST) Advanced Manufacturing Technology Consortia (AMTech) Program Award Number: 70NANB14H056
UNH - 28 October 2016
Sheet Metal Forming

14. 1.4 Development of Sheet Metal Manufacturing Training Courses
Project Description: Develop training courses addressing the concerns determined from the Roadmap of Stamping Supplier Training Needs
Based on results from the industry survey just described, a program can be developed to assist the sheet metal forming industry in better using their employees' talents and developing their skills.
UNH - 28 October 2016
Sheet Metal Forming

15. 1.4 Development of Sheet Metal Manufacturing Training Courses
Once You Discover Something New
Do You Have the Talent to Execute?
The value of research investment is constrained by the capabilities of those charged with development and implementation.
The lack of skilled manufacturing talent remains an issue.
As automation, technology, and materials evolve, manufacturers will need to develop and maintain employee skills in such things as
How different sheet metals behave in different applications like bending, shearing, and forming
Troubleshooting and Root Cause Analysis
Practical use of common software applications
Teamwork
UNH - 28 October 2016
Sheet Metal Forming

16. 1.4 Development of Sheet Metal Manufacturing Training Courses
Advantages of a Well Trained Workforce
PRODUCT QUALITY
LOWER FAILURE RATES
EMPLOYEE ENGAGEMENT
PROFITABILITY
Increased knowledge of material behavior characteristics will better prepare forming companies for new and alternative sheet metals and new technologies.
Specific benefits include:
Better quality formed components by improving the selection of materials, technologies, and tooling for forming activities.
Reduced scrap rates from reduced wrinkling, splitting, and excessive thinning.
Greater employee and management participation in problem solving and preparation for future requirements.
Greater industry profitability from better use of simulation, reduced waste, and greater employee efficiency.
UNH - 28 October 2016
Sheet Metal Forming

17. 1.4 Development of Sheet Metal Manufacturing Training Courses
Path to Implementation
Determine Industry Requirements from Training Survey
Prioritize
Develop Online and Classroom Training
The Training Needs Roadmap will be used to develop and implement a managed professional development program to address the greatest knowledge deficiencies in the sheet metal forming industry.
On-line and classroom training and development programs will be developed, based on the requirements of the topics and the ease and convenience of training recipients. Some topics could be addressed on-line, while others may be best covered in person.
Courses will include both technical knowledge and the explanation of how that knowledge can be applied to improve manufacturing performance.
UNH - 28 October 2016
Sheet Metal Forming

18. 1.4 Development of Sheet Metal Manufacturing Training Courses
Written details of the proposal follow on the next 3 pages
UNH - 28 October 2016
Sheet Metal Forming

19. 1.4 Development of Sheet Metal Manufacturing Training Courses
Objective: Develop a training plan and appropriate training content to address the greatest deficiencies in the sheet metal forming industry as defined by the Roadmap of Stamping Supplier Training Needs. Develop introductory and in-depth training programs using the most efficient delivery (on-line or classroom) for the topic.
Technical Benefits:
Having 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.
Having better knowledge of the inputs that affect product quality allows for improved designs that can produce a more robust manufacturing operation.
UNH - 28 October 2016
Sheet Metal Forming

20. 1.4 Development of Sheet Metal Manufacturing Training Courses
Technical and Non-Technical Obstacles:
Most training is offered by Professional Organizations that have a specific audience which they target, and do not emerge out of this silo.
For example, an association whose membership are manufacturing companies will not typically have expertise in lubrication, sheet metal production, tool steels, or how all of these individually and collectively impact forming success.
Training is typically offered in person, with the recipient needing to travel to the meeting location.
Due to cost and timing constraints, only selected people are sent, even though others might benefit.
Developing training materials for the most efficient delivery will better allow for transfer of knowledge and encourage greater participation.
Some topics may be better addressed in person or through live webcasts; other topics may allow for asynchronous presentation.
UNH - 28 October 2016
Sheet Metal Forming

21. 1.4 Development of Sheet Metal Manufacturing Training Courses
Path to Implementation:
Use the results of the Training Needs Roadmap to develop and implement a managed professional development program to address the greatest knowledge deficiencies in the sheet metal forming industry.
Develop on-line and classroom training and development programs, based on the requirements of the topics and the ease and convenience of training recipients.
Courses will include both technical knowledge and explain the application of that knowledge to improve manufacturing performance.
UNH - 28 October 2016
Sheet Metal Forming

22. 1.4 Development of Sheet Metal Manufacturing Training Courses
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