Implementation of FEA, Software Nesting and Quality Management Strategies for Enhanced Production: A Case Study in Sheet Metal Fabrication

Abstract

Sheet metal fabrication involves cutting, forming and joining processes to convert metal sheets into finished products. However, issues like trial-and-error prototyping, sub-optimal material utilization, and quality problems affect competitiveness and productivity. This study presents a case analysis of manufacturing optimization initiatives implemented at a sheet metal production company. Finite element analysis (FEA) was adopted to evolve the stamping dies through computer-aided engineering simulations. Nesting software was deployed to maximize material utilization during cutting. ISO 9000 based quality management system was instituted for quality assurance across production. The benefits from these initiatives were investigated via productivity metrics tracked over a two-year period. The results showed 20% faster die design turnaround from FEA-enabled virtual prototyping. Software nesting increased material utilization by 18% and reduced scrap generation. Process control and SPC implemented under ISO 9000 enhanced first-time quality yield by 22% and lowered rework. Production capacity increased by 27% over the analysis period enabling faster order turnaround and enhanced competitiveness. Thus, the performance improvements validate FEA, nesting software and quality systems as invaluable techniques for boosting production efficiency, utilization, and quality in sheet metal fabrication. The case study provides practical insights into leveraging engineering optimization for competitive advantage.