Aluminum Extrusion Process Analysis and Training

At JEL Enterprises, our Aluminum Extrusion Process Analysis and Training services include process analysis, equipment evaluation, die management, and employee training and evaluation.

The key elements of our aluminum extrusion process analysis and training include accurate data and employee involvement.

Questions you may want to ask are:

• Is our aluminum extrusion process in control and capable, and what systems are in place to measure?
• Are we running our existing equipment as effectively and efficiently as we can?
• Are our employees working as effectively and efficiently as they should?
• How do we compare to other companies in our industry in terms of performance?

Using industry metrics we compare your aluminum extrusion plant with benchmarks and "like" equipment to find out where your operation is in relation to benchmark data. Then we develop a plan of changes which can lead to incremental performance increases in your aluminum extrusion process.

This Benchmark Data chart assumes your aluminum extrusion presses are older, and were installed before 2006:

Aluminum Extrusion Process Analysis

Our Aluminum Extrusion Process Analysis service begins with a process audit and then development of a plan going forward based on the audit results. The audit will be a detailed analysis and establishment of baseline metrics based on observations and meeting with team members.

Aluminum Extrusion Equipment Evaluation

• Evaluating the condition and usage of your aluminum extrusion equipment.
• Identifying and quantifying savings and costs for resolution of nagging equipment problems.
• Verifying an EFFECTIVE work order system which includes PM's and TPM's.
• Ensuring the data is being used to prioritize maintenance work orders.
• Collecting data and evaluating trends.
• If a SCADA system is in place, we evaluate elements and potential improvements.
• We evaluate your data after or during production and collection of data.

Historical Heartbeat and Production Stacked Bar Graphs

Aluminum Extrusion Die Management

Data Collection Documentation

For aluminum extrusion dies needing repair, the data and feedback is sent back to suppliers. Working together, the actual results and repairs are documented. For clarity, pictures of noses and samples, and actual repairs, must be saved on the server. All repairs must include electronic die design, pictures of noses, repairs, and front ends, and are collected in a specific "check sheet" or procedure which is used to document performance and repairs. By tracking this information and sending it back to the supplier, subsequent copies of aluminum extrusion dies will perform at a higher level.

The difference between a good aluminum extrusion die design and a great die design are small details. Training employees to do a periodic die design review with suppliers based on the family of parts is critical.

Here is how our team at JEL Enterprises handles new aluminum extrusion dies:

1. Inspect incoming die
2. Extrude shape – Collect samples, die repair slip and other pertinent information
3. Inspect metal, contour and document
4. Make changes - Take pictures, mark up design print, and forward to supplier
5. Work with supplier to make any necessary corrections
6. Document die management

Die Technicians Polishing Dies

Die Technicians Polishing Dies

Aluminum Extrusion Employee Evaluation and Training

The key to training aluminum extrusion employees is checks and balances to understand if the training was effective. This can be achieved by observing aluminum extrusion operators doing their job, as well as understanding the job description and skills matrix, and verifying job expectations. These help us determine the type of training that needs to be done. We also have many training documents available.

Our employee evaluation and training includes:

• Evaluation of aluminum extrusion employee job descriptions and training skills matrix.
• Evaluation of press operators. Do they understand the heartbeat of the press and how their tooling performance affects the overall press performance?
• Reduction of waste and scrap, including understanding of definitions, possible causes, and resolutions.
• Analysis of evolution of press operators, die correctors and team leaders into technicians, focusing on quality and productivity.
• Evaluation of employee effectiveness and limitations.
• Analysis of personnel and the ability to perform tasks. Are the right employees being utilized for the right roles and functions? This ensures employee's work is based on company's needs.
• Evaluation of employees, including attitude and aptitude to perform the job.
• Are there meaningful goals and metrics which have been established and clearly explained to all plant employees? What is being done to collect data on an ongoing basis to ensure we are moving towards the clearly defined goals?
• Reliance on visual operational tools, integrated with checks and balances if possible.

Contact Us for Aluminum Extrusion Auditing, Evaluation, Training, and Improvement

Call JEL Enterprises at 609-321-5283, or email us, to find out how we can improve the productivity and profitability of your aluminum extrusion processes.