Molds are tools used to shape products, for example, in manufacturing processes such as plastic molding or metal fabrication.
Changing mold stages is a necessary operation when producing products with different shapes and dimensions. When different products are produced on the same production line, the molds must be changed. Since changing molds is a time-consuming and labor-intensive process, reducing the changeover time can improve productivity and reduce costs.
In this issue, we will introduce a case study in which five processes that were taking a long time during changeover were picked up and reviewed, thereby contributing to a reduction in changeover time.
(1) Reduction of die carrying time
Before the improvement, the mold storage area was located on the opposite side of the aisle. After the improvement, the mold storage area was located near the molding machine.
After the improvement, the mold storage area was placed near the molding machine, thereby reducing the time required for transporting and searching for molds.
(2) Reduction of nozzle heater removal time
Before the improvement, the nozzle heater was removed by using hexagonal wrenches to remove bolts at three locations. After the improvement, the work time was drastically reduced by installing three patch locks.
(3) Reduced mold setting time
There are two types of locating ring diameters for molding dies: 100 mm and 120 mm,
Before the improvement, adjustment was made by mounting and dismounting the ring on the molding machine side according to the molding die.
After the improvement, a ring adapter was installed on the molding die side to unify the two diameters to 120 mm, reducing the work required to change the rings on the molding machine side.
(4) Reduction of hydraulic clamp lock operation time
The thickness of the mold mounting plate varies depending on the mold specifications, so when mounting the plate on the molding machine, a special spacer was inserted into the hydraulic clamp to adjust the thickness.
Before the improvement, the thickness was adjusted by inserting a special spacer into the hydraulic clamp.
After the improvement, a steel material is screwed to the mounting plate to achieve the specified thickness, allowing clamping without the use of spacers.
(5) Reduction of input/checking of hot runner controller setting values
Before the improvement, the hot runner temperature controller/injection mode controller settings were manually entered and confirmed.
After the improvement, manual input was reduced by using memory settings and recalling conditions.
Various other processes remain to be improved, and we will continue to improve them.
In this case, by reviewing the above five processes, we expect to be able to reduce the changeover time from about 14 minutes to 10 minutes.
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