Changing molds (dangae) refers to the process of changing molds in a manufacturing process.
Molds are tools used to create the shape of a product, for example, in manufacturing processes such as plastic molding or metal working.
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 time-consuming and labor-intensive, reducing the changeover time can improve productivity and reduce costs.
One of our president's policies is "3-minute changeover.
This means that a series of processes from changing molds, connecting cooling pipes, and picking up materials should be done in 3 minutes or less. To achieve this goal, it is important to review the tools and processes used.
First, please take a look at the video of the stage change.
[Improvements]
(1) Before improvement:
The forward/reverse speed of the injection unit was slow, causing stoppage of the stage change operation.
(Because the clamp cannot be released until the injection unit is lowered to the maximum retraction limit.)
After improvement:
The setting was changed so that the clamp can be released even when the nozzle is not at the maximum retraction limit.
Minimum Maximum is indicated on the display.
(2) Before improvement:
Air purging of temperature controllers was performed, resulting in time loss.
After improvement:
Air purge operation was eliminated by changing to a coupler that opens and closes both ways.
At the same time, air entrapment in the mold and rust clogging were eliminated.
(3) Before improvement:
The next mold was prepared at the mold storage area on the clamping side of the molding machine, and the mold was
replaced.
After improvement:
Two cranes are used and the next mold is placed on the next molding machine to eliminate wasteful crane movements.
(The vertical axis of the cranes is slow, so we analyzed the movement of the cranes to use the left and right axes as much as possible.)
(4) Before improvement:
Mold shaking was severe during loading of molds, and it took time to suppress the shaking.
After improvement:
A plate is attached to the molding machine, and the mold can be lowered smoothly by lightly placing the mold on the
plate when it is brought in.
The mold can be lowered smoothly. This has the effect of preventative maintenance of the traveling rail unit.
5) Others
Review and revision of work procedures
One-touch mold opening stopper
Modification of the take-out machine program
By improving the above 5 items, we were able to achieve the target of 3-minute changeover.
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