Metal Stamping Line Machine Condition Audit

Full-line condition audits for Uncoiler → Straightener → Feeder → Power Press — data-driven inspections to prevent breakdowns, improve quality and extend equipment life across Malaysia.

What the Condition Audit Is

Our Machine Condition Audit is a structured, on-site evaluation of your entire metal stamping line that measures actual operational behaviour and identifies hidden failure points. Instead of waiting for a breakdown to reveal weaknesses, this audit surfaces early signs of wear, misalignment and control issues so you can act proactively.

Why it matters

Early detection reduces unplanned downtime, protects dies and tooling, ensures consistent part quality, and supports smarter CAPEX decisions. A single, well-timed audit can save weeks of lost production and large repair costs.

Audit Scope & Inspection Points

Area	Inspection Points	Benefit
Uncoiler & Coil Line	Coil tension & straightness, decoiler feed consistency, motor & bearing condition.	Reduce coil deformation and feeding interruptions; smoother upstream feed.
Straightener / Leveler	Roller alignment, crown adjustment, strip flatness checks and feed-through inspection.	Better strip profile, fewer take-up issues, consistent stamping entry conditions.
Feeder (NC / Servo)	Feed pitch accuracy, encoder & sensor health, clamp pressure, synchronization with press.	Improves part accuracy and prevents die damage from misfeeds.
Power Press Mechanical	Slide parallelism, bolster flatness, crank/web wear, bearing play, stroke consistency.	Ensures correct forming geometry and reduces uneven tonnage wear on dies.
Tonnage & Force Distribution	Actual tonnage measurement across slide positions; verify load distribution and press calibration.	Prevents under/over-pressing, protects dies and avoids quality variation.
Controls & Safety	PLC/drive diagnostics, encoder signals, E-stops, light curtains, interlocks and emergency stop checks.	Improves machine safety and reduces false trips or control-related downtime.
Lubrication & Maintenance	Lubrication status, oil condition, grease points, maintenance records verification.	Supports preventive planning and extends component life.
Vibration & Structural Check	Vibration spots, foundation integrity, fastener torque and machine anchoring.	Detects early structural issues and prevents progressive failures.

Audit Process — Step by Step

Pre-Audit Briefing: Understand production profile, recent failures and audit goals.
On-Site Measurement: Level checks, slide parallelism, tonnage mapping across stroke positions, feed accuracy tests.
Electrical & Control Checks: Read faults, inspect encoder signals, check PLC logs and safety circuit integrity.
Operational Load Tests: Run progressive test parts to capture real-world behaviour and detect intermittent faults.
Data Collation & Analysis: Compile measured values, vibration readings, and alignment data for diagnosis.
Report & Action Plan: Deliver a prioritized audit report with corrective actions, estimated costs and maintenance schedule.

Frequently Asked Questions — Condition Audit

How long does a full-line condition audit take?

Typical audits for a single stamping line take 1–3 days depending on complexity and number of processes. Larger or multi-line audits are scheduled and quoted separately.

Do you measure actual tonnage?

Yes. We perform tonnage checks at multiple slide positions to map force distribution and identify imbalances that affect part quality and die life.

Will we receive a formal audit report?

Every audit concludes with a written report including measured values, photos, prioritized recommendations, and an estimated budget for corrective actions.

Can audits help reduce scrap and warranty rejects?

Absolutely — by improving feed accuracy, press parallelism and tonnage consistency, audits directly reduce dimensional variation and scrap rates.

Are older machines suitable for auditing?

Yes. Audits are particularly valuable for older presses to identify refurbishment needs and to plan upgrades or safe-retirement timelines.

Do you provide follow-up implementation support?

Yes. We offer prioritized implementation — from tuning feeders to recalibrating tonnage — and can provide preventive maintenance plans to ensure recommended measures are sustained.

Can you audit multiple lines across the factory?

We can schedule multi-line audits and provide an aggregated health dashboard and roadmap to help you prioritise investments by risk and ROI.

Related Services

Consultancy & Advisory
On-Site Repair & Service
Installation, Relocation & Clearance

Schedule an Audit

Priority audits & multi-line discounts available — enquire for a quote.

GL Engineering Support Sdn. Bhd. — Professional condition audits for Malaysia’s metal stamping industry. Data-driven. Practical. Actionable.