Case Study | Standardizing Tooling to Run at 100 SPM
Case Study
Standardizing Tooling to Run at 100 SPM
At a Glance
| Category | Details |
|---|---|
| Customer | A Texas Based Customer |
| Scope | Refurbishment, modification, and standardization of all production dies, plus evaluation and fit-up of additional tools to the press. Prior to these improvements, the dies were operating at speeds ranging from 40 to 60 strokes per minute. |
| Target | Run products at 100 strokes per minute (SPM) |
| Result | 6 dies running at 100 SPM, with a consistent set-up standard applied across the tool set |
| Benefits | More available press capacity, lower cost, better on-time delivery and consistent part quality |
The Challenge
Customer runs a family of progressive dies that were built at different times and to different standards. Each tool had its own quirks: worn or mismatched details, soft anvils that warped parts, loose punch buttons, cut-off and lance sections with the wrong geometry, and no common way of locating the die in the press.
Those differences kept some tools from running at full speed and made every changeover a little different from the last.
The result was lost press time, frequent sharpening and repair, and less predictability in delivery. The customer’s goal was to run its products at 100 SPM, and to do it reliably.
Our Approach
Rather than treat each die as a one-off repair, FKI USA evaluated the whole tool set and applied a common standard. Each die was inspected, quoted, refurbished and then tested in the press.
Replaced what limited speed and quality
- New punches and die buttons, re-timed to the press
- Rebuilt lance punch and die sections where the original geometry caused frequent sharpening
- New cut-off and scrap cutter sections to restore full tool life
- Hardened stamp anvils to eliminate warped parts
Standardized how every die sits in the press
- Machined and mounted parallels, center locator blocks and clamp feet
- Stop blocks and top plates added for consistent handling
- A common feed line and shut height target across the tools
- Year stamps and part-stacking fixtures added where needed
Made the tools easier to keep running
- Secured loose buttons and fixed cut-off sections that were missing dowels
- Staggered punches to improve strength and reduce mishits
- Sorted and inventoried all punches and buttons so spares are identified and ready
- Year stamps and part-stacking fixtures added where needed
Every die was run in the press before sign-off, assuring the changes were proven in production conditions rather than on the bench.
The Results
- 100 SPM achieved: As of June 9, 2026, all of the dies in the program were confirmed running at 100 SPM.
- More available capacity: Faster, more consistent cycle times free up press time for additional work.
- Lower cost: Fewer repairs, less frequent sharpening and fewer crashes.
- Better on-time delivery: More predictable run rates and shorter changeovers.
- Consistent quality: Standardized details and hardened anvils hold part geometry from run to run.
Why It Worked
The improvement came from treating the dies as a system instead of a set of one-off repairs. FKI USA standardized the locators, parallels, clamp feet, anvils and spares, so every tool sets up and runs the same way.
What works on one die works on the next, and that consistency is what lets a shop run fast without giving up quality. That consistency is what lets a shop run fast without sacrificing quality.
Talk to Us About Your Tooling
Are your dies holding back production? FKI USA will run your parts, diagnose tooling issues that impact speed and quality, and implement proven solutions to optimize performance. From die evaluation and refurbishment to complete standardization, we help manufacturers achieve higher press speeds, greater reliability, and lower operating costs.