Choosing a partner for the automotive metal stamping process can feel daunting. How do you know which supplier will do right by you? Will they deliver a quality product? Will you get the just-in-time shipping you expect? All of these are valid concerns. That’s why we’ve developed this guide. Below, you’ll learn the steps to the automotive metal stamping process and what you should expect from a qualified supplier. Let’s dive in.

Step 1 – Engineering and Design for Manufacturability (DFM)

During this process, your manufacturer should engage in early supplier involvement principles. They’ll work with you to do a tooling risk assessment and optimize part geometry for the best manufacturing results. They may also perform simulation and prototyping at this stage.

Step 2 – Tool and Die Design and Build

In this stage, your manufacturer will create the tooling for your products. They’ll either opt for a progressive die or a line die, depending on your needs. Progressive dies perform multiple stamping operations in a single press stroke. These dies are best for high-volume, high-speed, and precise production applications. Conversely, a line die will use stations for each step. This requires more operator involvement, but is best for larger, more complex, or lower-volume parts.

At this stage, your manufacturing partner will also select the tooling material. They’ll evaluate your needs and match you with the right option for long-term success. Additionally, they’ll create a lifecycle plan. This is an overview of the comprehensive management of a die from design and acquisition through operation, maintenance, and final disposal.

Your partner will have the opportunity to either create the tooling in-house or subcontract it out to another provider. Typically, it’s best to go with a partner who creates tooling in-house. Compared to other options, in-house tooling significantly reduces lead times, cuts costs, and improves quality control by eliminating third-party bottlenecks. You’ll usually experience faster repairs and superior consistency as engineers and toolmakers collaborate on-site to immediately address issues. At Die-Matic, we create all our tooling under one roof to provide the best service for our customers. We also supply Gantt files to our customers, updated every two weeks during the tool build.

Step 3 – Production Stamping Operations

After the tool is built, it can move into production. Presses will range from 30-1,000 tons, and your partner will have to match the press size to material thickness and part geometry. Some manufacturers will have automation and feed systems that can load, position, and unload materials in a stamping press without manual labor. This maximizes production speed and gets you to market faster. Automation is particularly helpful for multi-million run parts.

Step 4 – Quality Control and APQP Integration

Quality control is extremely important throughout the manufacturing process. Your partner should follow Advanced Product Quality Planning (APQP) standards. It provides a framework of techniques that focus on proactive, early error prevention, risk management, and cross-functional communication.

Along with that, your manufacturer should follow the Production Part Approval Process (PPAP). This is a standardized, 18-element framework used primarily in manufacturing to ensure suppliers understand customer requirements and can consistently produce quality parts.

During the manufacturing process, your partner should complete dimensional inspection to ensure parts are meeting specifications. They should also offer lot traceability for enhanced quality control.

Finally, your manufacturer should follow industry standards like IATF 16949 and ISO 9001 systems. ISO 9001 is the internationally recognized standard for a quality management system. It defines criteria for consistent, high-quality products and services. IATF 16949 is based on the ISO 9001 system, but is specifically designed for automotive production. Following these standards gives you the peace of mind that your products will be made correctly every time.

Step 5 – Tool Maintenance and Process Stability

Your manufacturing partner should also offer tool maintenance and process stability. This includes things like tool wear tracking and preventative maintenance. Prioritizing these processes ensures that your tooling will last and will help avoid tolerance drift. This long-run stability reduces risk throughout the manufacturing process and helps protect your bottom line.

Automotive Applications That Demand Process Discipline

All automotive parts need close attention to detail to ensure consumer safety. However, there are a few applications that require even more process discipline. These include structural brackets, EV battery supports, sensor housings, reinforcement components, and interior stamped assemblies. If you’re working on any of these projects, it’s important to work with a trusted manufacturer like Die-Matic.

What Procurement Teams Should Evaluate in the Automotive Metal Stamping Process

When evaluating potential automotive metal stamping process partners, what should you look for? The first thing is tooling ownership. As mentioned above, in-house tooling provides a range of benefits versus outsourced options. If your potential partner offers in-house tooling, you’ll likely experience fewer setbacks and get to market faster. It’s also helpful to evaluate the depth of knowledge on the engineering team, as they’ll set the foundation for the whole project.

You should also consider the press capacity range. If a partner has more variety in their press capacity, they’ll be more likely to meet your needs long-term. Additionally, you should look for certifications like IATF 16949 and ISO 9001. These certifications prove that the manufacturer is dedicated to quality management and are a good indicator of whether you’ll receive quality products.

ERP/EDI capability and ASN support also become important throughout the automotive metal stamping process. Enterprise Resource Planning (ERP) and Electronic Data Interchange (EDI) refer to a manufacturer’s ability to manage internal operations through an integrated software system. At the same time, it ensures that the manufacturer can seamlessly communicate with partners by sending standardized business documents. This is crucial because it enables real-time visibility into order status, inventory levels, and more. ASN support doubles down on this capability by offering electronic notifications of a pending delivery. In the automotive industry, this is a necessity for just-in-time shipping.

Strengthen Your Automotive Stamping Process With Die-Matic

When you need a partner you can trust for the automotive stamping process, turn to Die-Matic. With in-house tooling capabilities and U.S.-based production, we’re a trusted partner for many automotive companies. We have ISO and IATF systems that ensure we’re providing high-quality components for every run. Combined with DFM collaboration and a large press capacity range, we’re ready to take on even the most challenging projects. Trust us for stable long-run programs. Contact us today to get started.