Rooster's Revenge

The job scene for die guys is picking up here in the Motor City. Personally, I think it because there is more high strength and super steel automotive stampings than die knowledge. This always leads to more processing and more simulations than normal. Elongation limits be damned!

At any rate, I have been getting a call or email at least once a week for several months now that go something like, “do you know anyone for this position?”. Since I am still trying to prove I am smarter than the guy who invented the Toyota Matrix, I am not interested. But, I thought you all may be interested in this cool opportunity:

My pal Jennifer Mitchell, a recruiter from ELI, has an opportunity for a Senior Simulation Engineer that knows AutoForm. Here is the lowdown on what looks like a sweet gig:

Location: Troy, MI

Summary
Responsible for establishing stamping processes and engineering estimates utilizing FEA simulation software(s) in an Advanced Engineering Group while considering best practices for materials, manufacturing and cost. Support product engineering, FEA and R&D departments in the design of components and systems. Support divisions and alternative (prototype) manufacturing as requested.

Essential Duties May Include

- Review product and establish stamping process considering and applying best practices for manufacturability and cost
- Fluent in AutoForm (PamStamp, Hyperform, Dynaform a plus) – conduct pre and post processes, perform engineering anaylsis to support feasibility and manufacturablility
- CAD experience (CATIA, Unigraphics and/or AutoCAD
-Working knowledge of GD&T
- Understanding of assembly/weld processes in cold and hot stamping
- Estimating experience to establish tooling and manufacturing process engineering estimates
- Knowledge of steels (raw and tool) and steel properties
- Support product engineering / FEA in feasibility of component and system design to provide maximum customer value and functionality while obtaining operational performance at optimal costs
- Support product engineering / FEA in conducting research studies to develop new concepts
- Support product engineering / FEA in development and completion of failure mode effects analysis (DFMEAs), design for assembly (DFAs), manufacturing (DFMs) and geometric design & tolerance (GD&T
- Support divisions upon request
- Support alternative (prototype) manufacturing upon request
- Compose and release reports to support simulation activities and/or manufacturing feasibility results
- Support/attend technical reviews-presentations at divisions and/or customer

Qualifications
Education -  Required: Bachelor’s Degree
Years of Experience: Minimum 6-10 years related experience in stamping environment required
Licenses and Certifications: Tool and Die Maker or Tool Maker a plus

Other Qualifications: “Hands-on” experience preferred. Experience using AutoForm and/or PamStamp. CAD system experience (ie. AutoCAD, CATIA, Unigraphics) a plus

If you are qualified and interested, please click here to contact Jennifer.

The quoting methods in the stamping industry are a blend of black magic and bullshit.

You have your good old fashioned Sight Method. That is where someone looks at the part and says, “That is a $250,000 die right there.” How the fuck do they know that? “Experience.”

Then, there is the Length-of-Line Method. You know that one. Measure some trim lines, a few form break lines, then multiply some random number to the length to get your quote. Now, if only you were selling line measurement services instead of stamping dies …

Next up on the list of fancy quoting tools is The Matrix. This works alot like an Ouiji Board. Find the row that has your blank area dimension, then find the column that has the number of stations. It points you to the price. You can almost hear some dead estimator whisper the price to you from the die graveyard.

My favorite is the BOM Method. This is the Bill-of-Materials-thing-a-ma-jig that bases the quote on a standard stocklist of items found in a tool. A guide pin here. A spring there. Keep in mind that the component prices are someone’s best guess and not real numbers. The theory is if you know the component costs, you can creatively guess at the cost of the tool. Somehow.

Here is where all these methods suck: The customer says your price is 30% too high. How could they know that? Using the above methods, you don’t even know if you are high, low, or somewhere in between.

Wouldn’t it be nice to go back to the customer with a rational breakdown to show them that your price is 5% above cost and there is no room to take out another 25% if they buy it at cost?

I would really like to see companies that are looking for a quote to build a die to stop asking for dollars and cents and start asking for hours and pounds.

Why?

Because the cost drivers in any die are machine hours and material pounds. It is that simple. Everything else has a direct relationship to machine time and material weight.

Estimate the 2D and 3D machine time (including wire and sink EDM, of course) and the amount of material required to get the job done, and you will be able to determine the real cost and prove that cost to the folks that think they can put the “your prices are too high” gun to your head.

Most days these days, I feel like Jack Bauer. You know what I mean. One long day of everyone gunning for you.

Today marks the 24th anniversary of my first day on the UAW / GM Die Engineering Apprenticeship Program.

24.

It has been a good ride overall. I am proud of what I have accomplished in this business. More so, I am grateful for the respect and recognition you all have bestowed upon me. Thanks for reading (I will try to get back on a regular blogging schedule …)

All the best to my brothers and sisters from our famed apprentice group. In no particular order, Happy Anniversary to Sherm, Danno, JJ, Flash, Booger, Bone, Hobnobber, TT, Ian, Gaspare, and Dougie.