The functional build approach to die tryout in the automobile industry

Abstract

This paper presents a technique for modeling the time saving potential of the "functional build" approach to die tryout in the automobile industry. During die tryout, tool and die suppliers often perform lengthy die rework when attempting to satisfy stamped panel specifications. Yet the rework is often unnecessary because in-spec assemblies can be made from out-of-spec panels. Functional build attempts to identify such opportunities to reduce die rework by allowing engineers to examine assemblies prior to making die rework decisions. However, the time spent coordinating the analysis may not be warranted. To predict the rework time reduction, optimal die rework policies, with and without functional build, are formulated. A numerical study of basic weld joint types gives insight about the effects of panel physical characteristics, supplier capability, and two common organizational restrictions on the value of functional build.