TABLE OF CONTENTS 

1. INTRODUCTION ....................................................................................................1 

1.1 Background ....................................................................................................1 

1.2 Research problem, targets and limits.............................................................2 

1.3 Thesis structure ..............................................................................................3

 2. LITERATURE REVIEW .........................................................................................4 

2.1 Reserch methodology and materials ..............................................................4 

2.1.1 Literature review..............................................................................4 

2.1.2 Case studies......................................................................................5 

2.1.3 Information analysis.........................................................................6 

2.2 Design ............................................................................................................7 

2.3 Programming..................................................................................................8 

2.3.1 Numerical control systems...............................................................9 

2.3.2 Manual part programming .............................................................11 

2.3.3 Computer-assisted part programming............................................12

2.3.4 Part programming using CAD/CAM .............................................13 

2.3.5 Manual data input...........................................................................15 

2.3.6 Nesting ...........................................................................................15 

2.4 Flat processing .............................................................................................17

 2.4.1 Laser cutting...................................................................................18 

2.4.2 Punching and forming....................................................................19 

2.4.3 Shearing .........................................................................................20 

2.5 Bending ........................................................................................................21 

2.5.1 Geometric tolerances......................................................................21 

2.5.2 Press brakes....................................................................................22 

2.5.3 Springback .....................................................................................25 

2.5.4 Bend allowance ..............................................................................25 

2.6 Assembly......................................................................................................27 

2.6.1 Joining processes............................................................................27 

2.6.2 Mechanical fastening .....................................................................30

 2.7 Cost structure of sheet metal parts...............................................................31 

3. INFORMATION AND OPERATION MANAGEMENT TOOLS........................32 

3.1 Basics of information and knowledge..........................................................32 

3.2 Product Data Management (PDM)...............................................................33

 3.3 Enterprise Resource Planning (ERP) ...........................................................34

 3.4 Computer-Aided Design (CAD) ..................................................................35 

4. CURRENT SITUATION........................................................................................38 

4.1 Available systems.........................................................................................39 

4.2 Transition to the new system environment ..................................................42 

4.3 Increasing the machine base.........................................................................43 

5. MAPPING THE SHEET METAL PROCESS .......................................................45  

5.1 Design process .............................................................................................45 

5.1.1 2D design with Microstation..........................................................46 

5.1.2 3D design with Pro E .....................................................................48 

5.1.3 Re-manufactured products.............................................................49 

5.1.4 Publication of drawings .................................................................50 

5.2 Part programming and nesting process ........................................................50 

5.3 Laser cutting, punching, and shearing process.............................................53 

5.4 Bending process...........................................................................................53 

6. CHALLENGES AND DEVELOPMENT ..............................................................55 

6.1 Information flow errors................................................................................55 

6.2 Human based errors......................................................................................57 

6.3 Revision management ..................................................................................59 

6.4 Avoiding manual work.................................................................................60 

6.5 Other observations .......................................................................................6

2 7. CONCLUSION.......................................................................................................64 REFERENCES................................................................................................................65 

APPENDIX A: Interview questions 

APPENDIX B: Process flow chart – CAD design phase 

APPENDIX C: Process flow chart – Part programming and nesting phase 

APPENDIX D: Process flow chart – Laser cutting, punching and shearing 

APPENDIX E: Process flow chart – Bending