Metal Stamping Quality
At Wiegel, quality is our number one priority. Our 80-year reputation is built on the quality of our stamping parts and the quality of our metal stamping production equipment and technology. We have achieved all the required industry certifications and have a dedicated quality lab and inspection team responsible for maintaining quality control at the greatest extent.
SOPHISTICATED QUALITY CONTROLS AND CONTINUOUS IMPROVEMENT
Our sophisticated quality control equipment includes a high-end Zeiss CMM, OGP smart scopes, Keyence vision systems, an ATOS laser measuring system, in-die sensors and camera vision systems. With the use of camera vision systems stationed at our production presses, part dimensions are captured with speed and accuracy based on advanced camera imagery as parts are stamped and making their way off the press. Our quality inspection team is responsible for production quality control and product protection, which involves in-process and off-process quality testing of metal stampings.
Wiegel also emphasizes continuous improvement throughout the organization. We have a dedicated continuous improvement team who meets weekly to review continuous improvement project efforts and action plans and discuss new project suggestions made by employees.
QUALITY IS A COMPANY-WIDE RESPONSIBLITY
Quality isn’t just one department’s responsibility—it’s the responsible of every team member at Wiegel. Quality must be embraced and understood by every team member employed, be it an office executive, a production operator, a materialhandler or a driver. No matter the role, everyone in our company does their absolute best to ensure quality is upheld in every part of our business. The adoption of our quality statement is expected from the hire of every new employee and continued on throughout long-term careers at Wiegel.
PREDICTABLE PRODUCTION WITH FEASIBILTY ANALYSIS
At the beginning of every production program, Wiegel conducts a feasibility study to determine if parts can be manufactured. During the feasibility, our project management and engineering teams will come together to review project details and ensure all part dimensions and forms are feasible for operation. If parts have any manufacturability issues, our team will work with customers to improve the part design and provide design suggestions to reduce cost and simplify the production process.
We also conduct process failure mode and effects analysis (PFMEA) to consider all production factors and sources to determine an error-free process. During this process, our Quality Department is responsible for making plans to prevent failures that could occur and to assist Project Management and Engineering Departments in creating a control plan for production.
We Prioritize customer satisfaction
At Wiegel, our utmost priority is customer satisfaction with the quality and integrity of our parts. In-die sensors, press monitoring systems, camera vision systems and a dedicated inspection team ensure parts leaving the production line exceed customer expectations.
QUALITY IN ENGINEERING
Our Engineering Department upholds our quality standards in the design process with expert knowledge, experience and proper design technique. Engineers start with the die design process by drawing on their experience of successful projects and previous engineering tests and trials and integrate knowledge of similar tools to make the best recommendations for new tooling projects. Our Engineers can design and run tools in a virtual production simulation to debug the production process and ensure parts run seamlessly when physical production takes place. Tool makers and engineers are involved in making recommendations and finalizing tool design before officially handing the project off to the Tooling Department to begin building the tool.
QUALITY AT THE PRESS
While parts are running in production, we have quality assurance camera vision systems incorporated at the press. Our vision system developers will utilize calibrated master part samples to test part strips and verify vision systems are working properly before implementing them in high-volume production. The vision systems will do 100% inspection of parts coming off the press with highly accurate camera imaging. The cameras built into the vision systems take pictures of the parts after parts move out of the tool and measure dimensions, forms, bends and holes compared with the part print to ensure a perfect match.
Press operators also perform a first piece and last piece inspection of parts at every run or specific cycle of parts. Operators utilize gaging tools at the press and bring sample parts into the Quality Lab to check dimensions of parts using automated quality lab equipment.
QUALITY IN THE TOOL ROOM
In the tool room, there are also quality processes while building and assembling the tool before running it in production. While the tool makers are building the tool from our engineers’ design, tool makers further test and debug the tool as they are assembling tool components. If tool makers realize any changes for the tool that will improve the design for production, they will provide suggestions to our engineers who will review and approve the design modification before updating the final design.
Our Tooling Department also integrates quality detection sensors into the tools that ensure quality during tool try-out and final production. Every tool has a minimum of two sensors per sub-die set. The tools include stripper sensors for checking slugs and misfeed sensors to make sure the material feed is in proper location while running in the press. Part ejection sensors are also applied to tools to make sure the parts leave the die while running in production. Our Automation Department is responsible for designing and producing our camera vision system and sensor technology and works closely with our Engineering Department to design the integration of detection sensors into progressive tools.
Once the tool is running in production, our tool makers are also responsible for quality maintenance of the tool. Tool tickets are assigned for tools requiring maintenance and state any operational problems or quality issues that need attention in the tool. Tool makers are notified every time the tool requires adjustment and at the last piece production run so tool makers can perform an inspection of the tool.
QUALITY IN THE LAB
In the Quality Lab, we conduct all our in-process inspection, capability studies and quality tests. We do calibration testing, PPAPs, feasibility testing and measurability of parts and their features and everything required to test and implement quality control before releasing the job into production. We initiate process planning based on customer requirements and incorporate inspection controls unique to every program. We make sure all critical part dimensions have been studied and will be in spec 100% of the time.
Sample parts are brought into the department to get approved prior to running in full production and our skilled quality engineers and inspectors measure part layouts and handle first-piece production run, last-piece production run and in-process inspection reports. We utilize high-level quality inspection equipment including SmartScope OGPs, a Zeiss Contura CMM and Keyence OGPs. The variety of this advanced quality inspection equipment allows us to measure flat and 3-dimensional parts accurately and efficiently.
We also have a dedicated safe launch team that is responsible for inspecting all parts during the pre-launch production phase. The safe launch team makes sure any production issues are corrected and the job is completely debugged before going into full production mode where there are zero issues.
STRICT SUPPLIER AND PARTNER SELECTION
We understand quality starts from the bottom of the supply chain—from material to small parts to assembly integrators and on to the OEM. All of our material suppliers and subcontracted vendors have gone through a strict supplier qualifying and approval process. Our small network of top suppliers are superior in quality, price and delivery. All production materials are inspected and approved before running in production and suppliers are required to submit a PPAP approval request for new production jobs.
FLAWLESS PACKAGING AND DELIVERY
Product packaging is just as important as the quality of the parts themselves. It’s important for suppliers to package using an efficient packaging method for parts and appropriate packing materials to ensure parts are safe and secure during shipping and transit. We use an internal database and customer portal to import specific packaging instructions provided by our customers and related to each individual part number. We offer a range of part packaging options such as bulk packaging, layered packaging, reeled packaging, cells, trays, boxes, tubes and others. We can also use recyclable packaging that can be reused between the customer’s shipments. Additionally, we can customize a unique packaging option to suit our customer’s parts and meet preferred requirements and packaging standards.
All packaging options are properly secured onto skids or pallets and edge protected on all sides. Then packages are banded and stretch wrapped to make sure parts adhere to the skid to prevent movement from the skid. We take all necessary precautions to prevent parts from being damaged during shipment to our customer.
We also incorporate a very strong shipment tracking procedure so we and our customers can follow each shipment all the way through its process. We ensure all packaging information is continuously updated in our system for proper labeling of barcodes and 3D labels. Using our customer’s preferred carrier, we will start by scheduling all shipment pick-ups and use an automated computer system to send out an advanced shipping notice (ASN) to our customer. This will tell customers information like the tracking number, how many parts are in each box, how many boxes are in each shipment, when they are expected to receive their shipment and other important tracking information. Our quality and efficiency procedures in our Shipping Department allows us to get parts out of our facility on-time for successful and timely delivery.
OUR PRODUCTION PARTS
Wiegel produces a variety of precision metal stampings made from copper, precious metal and ferrous metals. We specialize in manufacturing of both precision electrical connectors and non-electrical parts that are used in our world’s most demanded consumer products and essentials.
Family owned and operated since 1941, we’ve designed and built tool and dies for a range of metal stampings and metal formed parts with tight tolerances and stringent requirements including:
- Compression Limiters
- Crush Bushings
- Fuse Boxes
- Fuse Clips
- Heat Sinks
- Hose Clamps
- Lead Frames
- Lighting Components
- Press-fit Pins
- Rolled Bushings
- Selective Plated Lead Frames
- Selective Plated Terminals
- Terminals, Contacts and Connectors
- Wire and Cable Connectors
INDUSTRIES WE SERVE
It’s our mission to offer premier metal stamping and metal forming solutions to the most challenging and innovative engineering product designs. We combine advanced metal stamping production and tooling equipment, superior quality controls, seamless automation and production processes and a knowledgeable and experienced team to serve an array of market segments.
Wiegel lives by the philosophy of embracing the latest technology. We have regular technology updates and new equipment acquisitions so we can always have the necessary tools to develop breakthrough techniques and processes and deliver quality parts.Learn More
Wiegel is committed to production sustainability and efficiency. We train our team to conserve energy and resources and follow an ISO 14001 certified environmental management system that allows us to operate in an eco-friendly supply chain and stay compliant with industry standards.Learn More
Supply Chain Management
From the very bottom of the supply chain, we manage product material, metal stamping production, pre- and post- stamping operations as well as product handling, tactical scheduling, logistics and delivery. Wiegel helps manufacturing customers reduce their supply base by offering assistance in all phases of metal stamping production from early design concepts to tooling to production of finished stampings and assemblies. Customers can track projects with real-time updates and keep all teams aligned with project goals.Learn More