In a two-piece aluminum beverage can plant, the Tool Room is responsible for managing Bodymaker tooling, which is needing to form aluminum cups into the shape of the can body.   

Key tasks for the tool room include assembling tool packs and maintaining tooling inventory to ensure smooth production.

A Bodymaker tool pack is a set of tools used to form an aluminum cup into a can body. The tool pack includes:

1. Bodymaker Punch: Drives the aluminum cup through the dies.

2. Redraw Die: Reduces the cup diameter to the required size.

3. Ironing Dies (usually three): Progressively thin and lengthen the can walls to achieve the desired thickness and height.

Each tool must meet precise dimensional specifications, which are typically measured in the tool room using special measurement gauges. 

The tool room measures dimensions, and assembles new tool packs when needed.

Tool pack assembly relies on a progression chart, which defines the specific sizes and sequence for each tool in the tool pack. This progression chart ensures that each die performs the correct amount of metal forming, based on the punch selected.

By following the progression chart, the tool room ensures each die works correctly without overburdening any single tool, maintaining the balance of metal forming (not too much and not too little).

Once assembled, the tool pack is installed in the Bodymaker to start can production. These tools experience wear and tear from the high-speed forming process. Many plants grind the ironing and redraw dies (in-house) after each use. Grinding restores the die's critical dimensions (diameter and profile) and surface finish, allowing them to be reused several times.