How we work?

Proces realizacji projektu w DAGA to droga od koncepcji do finalnego produktu. Nie działamy na oślep – przebieg całego procesu wyznaczają precyzyjnie określone kroki.
Każdy etap jest dla nas równie ważny i stanowi nieodzowny element sukcesu naszych klientów. Zobacz, jak działamy, by przekształcić Twoje pomysły w rzeczywistość.

Projekt narzędzia

Projektujemy narzędzia (tłoczniki, wykrojniki) zarówno dla wielkoseryjnych produkcji i skomplikowanych komponentów, jak i małych serii produkcyjnych.

 “>Dobieramy najbardziej efektywną konstrukcję narzędzia dla Twojej produkcji – wielopostępowy/wielotaktowy wykrojnik najbardziej sprawdzi się przy większych produkcjach wymagających dużej precyzji i monitoringu kosztów, natomiast przy mniej wymagających procesach i produktach o niskim skomplikowaniu zaproponujemy rozwiązanie jednozabiegowe.

Przygotowujemy analizy wykonalności oraz wykonujemy na Twoje życzenie prototypy wraz ze studium koncepcyjnym sprawdzianów dla procesu kontroli jakości. Prace projektowe wykonujemy w środowisku SolidWorks.

Produkowane przez nas narzędzia wielotaktowe mogą mieć wymiary max. 1200 x 800 – to narzędzia przeznaczone do pracy na dwóch liniach wyposażonych w prasy mimośrodowe o nacisku max. 250 ton. Dla narzędzi jednozabiegowych oferujemy produkcje na liniach pras mniejszych – prasach o obciążeniu do 160 ton.

Na tym etapie będziemy projektować jakość dla całego procesu oraz wybierzemy odpowiedniego dostawcę surowca produkcyjnego. Taśma w krążkach, drut płaski, płaskownik – zasugerujemy najlepsze możliwe rozwiązanie istniejące na rynku, biorąc pod uwagę wymagania procesu, możliwości jakościowe centrum serwisowego oraz cenę i lead time potencjalnego dostawcy.

Tool Manufacturing and Assembly

Our in-house tool shop is responsible for the manufacturing and assembly of stamping tools. Beyond the structural elements of the die—such as the upper, intermediate, and lower plates—as well as standard components, we can produce all necessary parts ourselves. This is made possible by our extensive tooling facilities and skilled specialists in metal processing, including millers, grinders, turners, and toolmakers.

 Before final assembly, each newly manufactured component undergoes inspection in our measurement laboratory. As part of preventive maintenance for our clients’ tooling, every newly built stamping tool, die, or press tool is assigned a tool logbook. This document, prepared during the assembly phase, includes a planned maintenance and inspection schedule. Throughout the entire production lifecycle, the logbook is continuously updated with information on tool usage and servicing.

If you order production gauges from us, we will manufacture and validate them at this stage as well.

Internal Production Line Trials

Before the newly designed and manufactured tool is ready for production, we set up the necessary production line. This includes:
– A properly selected press with a feeder
– A decoiler to handle material supply
 We fine-tune the entire system using automation, ensuring it is fully optimized for your production process.

Preliminary Production

Process validation and the production of the first components represent the most challenging and highly anticipated stage. This is typically when we meet with you for an audit—covering both production and the project itself.
 For metal components susceptible to corrosion (e.g., black steel), we must ensure surface protection. This may involve galvanic or chemical coatings (e.g., phosphating) or painting.

In such cases, we rely on proven subcontractors and external service providers. During preliminary production, we always audit our suppliers and monitor their work to ensure compliance with our requirements.

At this stage, we conduct all additional quality tests, including those that must be performed outside our laboratory (e.g., technical cleanliness and material hardness tests). We also register the product in relevant databases, such as IMDS.

Submission of Initial Samples for Customer Approval

The process of submitting the first samples and required documentation for approval is carried out according to your requirements—this may follow the PPAP procedure, in which case we issue a PSW (Part Submission Warrant) quality guarantee. We have previously worked according to the requirements of Toyota’s supply chain, AIAG, and VDA.
 ZTypically, we provide a larger batch of products for validation in the customer’s process, such as 500 or 2,000 parts, along with a homologation sample that has undergone full dimensional inspection (layout inspection).

Final or Temporary Customer Approval

We strive to ensure that the design and approval process for new production runs smoothly. Our greatest satisfaction comes from obtaining permanent approval for production on the first attempt.
 However, if this is not possible, we proceed with temporary approval. If process improvements are required on our side, we implement corrective actions immediately.

If the issues are beyond our product’s scope, we take a proactive approach. Proposing and implementing new solutions quickly is not a challenge for us when necessary.

SOP (Start Of Production)

According to our internal requirements, the start of any production is closely monitored and thoroughly examined. Control plans cover both pre-series production and the initial production period after launch (known as the quality gate).

 The duration of heightened inspection and analysis of the product, process, and tooling is individually defined in the control plans. This depends on factors such as risk analysis results, process FMEA, special characteristics, customer requirements, and production batch sizes.

Process Monitoring and Modifications

Any modifications to an approved and running production process are introduced only in consultation with and upon approval from you. Requests for changes initiated by you are treated as a priority.
 We promptly determine their feasibility through a risk and feasibility analysis and assess the associated costs, allowing you to make informed decisions quickly.

Tooling Design

We design tooling (stamping and cutting dies) for both high-volume production of complex components and small-batch manufacturing.
 We select the most efficient tool design for your production needs—a progressive die is best suited for larger production runs requiring high precision and cost control, whereas for less demanding processes and simpler products, we offer single-operation solutions.

We prepare feasibility analyses and, upon request, develop prototypes along with conceptual studies of inspection gauges for quality control. Our design work is carried out in the SolidWorks environment.

The multi-stage tools we manufacture can have maximum dimensions of 1200 x 800 mm—these are designed for operation on two production lines equipped with eccentric presses with a maximum force of 250 tons. For single-operation tools, we offer production on smaller press lines, with presses up to 160 tons.

At this stage, we will define quality for the entire process and select an appropriate supplier for raw materials. Whether it is coiled strip, flat wire, or flat bars, we will recommend the best available market solution, considering process requirements, the quality capabilities of the service center, as well as price and lead time from potential suppliers.