Surveys undertaken in the German forging industry uncover the significance of defects and the reasons for their origin. Based on the survey methods and strategies have been developed specifically to eliminate the reasons of the defects.
The main reasons for interruptions are defects in the information flow between the planning and manufacturing departments. With a data bank system informations of the tool and process design will be passed to the manufacturing departments. In the reverse all defects during manufacturing and the introduced remedial measures flow back to the planning department.
The tool's state of wear are the main technical reason for interruptions during manufacturing. With the help of a new sensor technique, which is based on the use of eddy-current test probes, it is possible to objectively record the tool's state of wear.
Bearing damages or jamming billets are main reasons for interruptions at the forging press or peripheral machines respectively. Ideas for solving these problems are also being presented.