first-rate mold company plans to come out of the recent recession with numerous advantages for their customers in the injection mold and precision machining market segment. The advantages offered are a result of the company’s long-term commitment to automation technologies.
While first-rate mold company has been manufacturing injection molds for more than 20 years, their sustained commitment to automation continued throughout 2009 and the first part of 2010 with several additions to its manufacturing automation portfolio.
Automated Beginnings and Benefits
Initially, first-rate mold company found that adding tooling storage with a robotic interface produced higher production rates, increased productivity and resulted in better quality. “Our five-year plan was to bring in more advanced automation in early 2009.
Although counterintuitive, the timing couldn’t have been better when these purchases were placed on the production floor in early 2009. In the heart of the recession, we were able to implement the new equipment and get our training behind us, which has allowed us to accelerate out of the tough times and be ready for the opportunities that 2010 has to offer,” explains steven, VP Operations at first-rate mold company.
“A significant value-add we provide is our creative design capability. Automation begins in the design department and assists us in consistently executing our designs—providing our customers with very tight-tolerance molds,” notes steven president of first-rate mold company.
Some of the advantages offered to customers as a result of the automation additions integrated throughout 2009 include the following:
Cost control resulting in lower prices through more spindle time and lights out manufacturing. Automation also provides more efficient use of materials, cutters and other supplies.
Consistency with changing out parts the same every time with every part using the same “zero” throughout the manufacturing process.
Tight tolerances and in-process quality inspection.
Leadtime reduction through improvements in productivity, cycle time and accuracy.
Cavity interchangeability improvements through accuracy, inspection and consistency.
first-rate mold company’s automation now includes tool-to-tool robotics and storage facilitation capabilities.
The latest installation is the newly arrived Mikron HSM500 with simultaneous 4-axis capability integrated with their existing Erowa Multi-Twin Robot that was already mated to an Agie Hyperspark 2 Sinker EDM.
Robotic interface from the mill to the sinker is enhanced with additional pallet and electrode storage using the Erowa system capable of storing 45 workpieces and 210 electrodes. The second piece of automation purchased this year was an Erowa ERC Robot that is able to feed 10 workpieces and 132 electrodes into a Mikron HSM 300 Graphite Master.
a company has had to source robots that are universal enough for a variety of processes, and, consequently, that they have enough facility space to accommodate the setups. we should be also collaborating with multiple stakeholders on digital commissioning, or a digital twin, that will provide the level of flexibility the team needs. Getting to a stage where they can plan the entire engineering and production process virtually first means that they won’t waste time and money proving out physical prototypes, and that they’ll be ready to go when the project hits the shop floor.
How can die and mold shops compete against low-cost sources? a fledgling die and mold shop in china is doing it with automation. The 20-employee shop enjoyed a 38 percent increase in sales last year, and it expects to ring up another 20 percent increase this year. The shop operates only one attended shift, but automation keeps the machines running around the clock 7 days a week, making for low costs, high quality and very competitive delivery times. I don’t want to write out the name of this mold shop here, I’m afraid the webmaster of this site suspects me for advertising
What should you be looking at when considering automation? Start with your existing labor force. If you are having a hard time finding skilled operators, process engineers, or maintenance technicians, then automation can almost certainly help you achieve an increase in overall efficiency and quality. Automation almost always works faster and occupies less floor space than a manual operation. Automation systems also do not need breaks and can offer a consistency that manual operation cannot. The added consistency in cycle time not only improves product quality, but also can help you identify more accurate operating costs and production output. Automation can help you to become more successful when competing against other molders.
Does the automation fit well within your workspace? Everyone knows that floor space is valuable but “shoe-horning” automation into a space that is too small or poorly planned can, and most like will, directly impact the uptime of the entire molding cell. When possible, plan the workspace based on the automation or process requirements, making sure to provide an adequate area for the needed movements and actions performed by and on the equipment. Undersizing the work area can limit the optimization of the process and efficiency of the automation.
Even after parts are molded, automation can help increase overall efficiency and reduce total costs. Automation can be utilized right at the molding machine where you can retain control over parts through post-mold operations and even into final packaging. If the process can be done directly at the press using automation, there is no need to ship parts to and from warehouses for further processing. Automation decreases errors and defects and limits variables so that your company can focus on accomplishing tasks, not dealing with errors.
Deciding to automate is the easy part. The next, and more important step is determining how to best implement automation in your process and injection molding cell. you should look at and consider when determining how automation will best work for you and your company.
Don’t get the impression that to automate your process effectively, you need to go out and hire additional staff (although this is one solution and would more than likely lead to long-term benefits). Instead, the operators that you already have should be able to get the job done; they just need the right training and support. Your OEM supplier will likely offer this training at the point of installation. Take advantage of this and give your operators every chance to learn your automation system inside and out.
Of course the main point of robotic automation is to reduce human interaction. The key to successfully running any automation cell is to run it in automatic mode and to have operators interrupt the cycle as little as possible. The longer a cell runs in automatic production, the more that costs will be reduced through the efficiencies and optimizations that the automation can provide. When a cell runs automatically, it is much easier to recognize the actual costs of the operation and determine the volume of product that the cell can produce every hour, every shift and every week. When planning an automated molding cell, don’t forget to work with your automation provider to come up with solutions for staging inserts, queueing boxes for packing, using vision systems for quality checks, and doing whatever else may be needed to reduce the amount of operator involvement within the cell.
NX CAM includes tool-tilt controls, which make it easier to take advantage of five-axis machining. It automatically converts three-axis tool paths to five axes in order to efficiently machine molds with deep cavities. With tilted-tool machining, the shop can use shorter tools to reduce vibration, minimize tool deflection and improve surface finish.
The CAD/CAM software can automate other aspects of mold design, such as bill of materials creation, and users can save time by automating repetitive tasks with journaling and macro capabilities.
The user can perform a task once, the CAD/CAM software record it with journaling and save it as a macro to use on the next project. Additionally, the mold design libraries enable users to quickly compare revised and past part models, saving time on the updating process.
The mold shop uses NX CAM to program all milling operations involved in mold and die manufacturing.The NC programmers work directly from the CAD model and use NX design functions to design electrodes and prepare models for machining. everything will be no problem
The CAD tools are used frequently to extrude, unite and close gaps, and the “optimize face” capability can heal questionable part geometry without forcing the user to go through a multi-step process. the designers will save time
The excellent CAD/CAM software points out undercuts and places where more draft is necessary. The designer can look for thin or thick walls and automatically determine the mold’s total weight and center of gravity. With mold features readily identifiable, the design process progresses quickly.
The good CAD/CAM software still can automate other aspects of mold design, such as bill of materials creation, and users can save time by automating repetitive tasks with journaling and macro capabilities.
The designer can look for thin or thick walls and automatically determine the mold’s total weight and center of gravity. With mold features readily identifiable, the design process progresses quickly.
NX CAM is designed to enable multiple kinds of advanced machining, including high-speed machining, a key technology for moldmakers who need to quickly machine surfaces to a near-mirror finish.
Yes! I like NX very much! when customers send CAD models and requests for quote. The CAD models are usually in the STEP neutral interchange format, and our mold designer imports the geometric data into NX. After winning a project, then uses the specialized mold-design features of NX Mold Wizard to create the mold base and design cores, cavities, runners, cooling lines and other features quickly and efficiently.
Five-axis and high-speed machine programming functions in the CAD/CAM software enable the company to take full advantage of its advanced machine tools. By fully integrating mold design and machining, the software enables users to edit a CAD part, then seamlessly go back and forth between CAD and CAM, virtually eliminating room for errors. With this integrated system, the company established a digital thread that enabled process automation throughout design and manufacturing.
select the NX software suite from Siemens PLM Software, which includes specialized mold-design features in addition to traditional CAD/CAM capabilities. Key software characteristics automate parts of the mold-development process from design to manufacturing.
Industrial robots can be used to automate the injection molding process by using a pick-and-place robot to load plastic parts into the machine or to place the finished pieces onto a conveyor belt.
In fact, Industry 4.0 has gone in this direction, and the mold industry is the same.
Automation can and should be tailored to value-added assembly and custom projects. Custom injection molding manufacturers should always prioritize the needs of the customer, and when automation is effectively implemented in the manufacturing process, savings in both time and money are passed on to the customer.
There are many important benefits of automating your injection mold production. From reducing cycle times to improving part quality and consistency, automation on the whole can help create a more efficient manufacturing process. Add to that reduced labor costs and less waste during manufacturing, and automation is almost a slam dunk. Manufacturers like automation because it allows them to increase their machine utilization and create more consistent cycle times, so they can plan production more efficiently and profitably.
Industry 4.0 is gradually entering the manufacturing industry, but I think it will not be easy to achieve the popularization of industry 4.0, there are many technical problems to be solved
Automation of the manufacturing process is key to ensuring your end customers that your company will deliver the highest-quality product at a competitive price. Besides, injection molding robotics in the plastic industry provides numerous application benefits, including:
A consistent quality of the produced parts
Decreased costs of molding, labor, and finished product
Decreased part variations that in return reduces waste and increases yields
More consistent cycle times
Superior productivity and efficiency
Better flexibility
For the mold industry, this is not easy to achieve because of the particularity of mold production
I think it is not easy to implement fully automated production in the mold industry because of the particularity of the mold
Automation can be defined by mold manufacturers on many levels; however, the results—efficiency, productivity and accuracy—can probably be agreed upon by all. Implementing automation technology on the shop floor through cell manager software, combined CAD/CAM systems, robots and machines with in-process inspection will allow the mold manufacturing process to be completed as quickly and efficiently as possible—perhaps with less manpower.
Congratulations, you are on the right path, this is the trend of the development of the mold industry.
At present, complete automation is not wise for mold manufacturing.
yesterday I told my father who is the owner of a mold company about this blog,He admires your blog and thinks your blog will benefit a lot of peoples.
Hi! misty, if your father want to share his experience about mold technology, he is welcome any time!
The entire mold industry is moving in this direction,Your company is on the right track.
The mold industry is actually moving in this direction, and your company is on the right track.
The concept of automation should have different understanding for different mold company.
The philosophy of your company follows the development of The Times.
Your company’s business philosophy is right
Intelligent and numerical control is the trend of the development in mold industry, the big data is the foundation
Your idea is right, but maybe your local market needs it
Congratulations to your company, your competitiveness is gradually increasing
Your company’s marketing competitiveness has been enhanced
Automation is also a gradual process, although this is the trend of mold development
Congratulations! Your company’s development philosophy represents the development direction of the mold industry
In my opinion, traditional mold manufacturing techniques are still very useful
In my opinion, the traditional mould manufacturing process is still suitable for today’s mould manufacturing
thanks for sharing your idea about running a mold company
This is the development trend of the mold industry
It means that more and more people will lose their job in mold industry
hi this is Bea, last month we discuss this issue with you in your office, now I want to take back my words :-)
Hi Bea,This is just a normal discussion,There is no right and wrong, you are welcome anytime.
Intelligent manufacturing technology has been used in more and more mold manufacturing
now in the mold industry, there is more and more numerical control and intelligent mold factory
Your company will have a very good development prospect in the mold industry。
In this case, some peoples will be out of work in your company
Mold industry’s future development direction is automatic and intelligent
Maybe you are right, maybe…
Your company is going in the right way
many mold companies in Germany, Automation has been popular! please feel free to visit our company, maybe you could get more:-)
thanks for your invitation, as long as we have free time,We must go to visit your company
I don’t think this is a good news for our company. maybe you are right! maybe……
I don’t think this is a good news, because at least in mold industry, automation is not the most important part
I don’t think this is a good news for every mold maker, if anyone oppose it, we can discuss here
in that case, your market competitiveness has strengthened a lot
It just means you need to do like this for your business
but I don’t think this is a good thing, because mould is single-piece production, something is different between moulds.It just makes the production efficiency to improve
but I don’t think your idea is suitable for every mould company
Maybe this is your customer’s requirement!
So their competitiveness is becoming more and more strong
congratulation! your company is going in the right way!
this is the development trend of the mold industry
I still want to say, in my opinion, it really depends on your customer’s requirement, because The manufacturing cost is a factor which cannot be ignored
this is the trend of our mold industry
your company is very good
the making concept of your company is very good
your idea is correct!
this is the trend in mold industry
your idea about this issue is very good
first-rate mold company is first-rate mold company:-)
this is a trend in mold industry, your company is on the right way!:-)
I think your company must have good business in mold industry, otherwise, your company does not have that kind of idea
I appreciate your company
your company keep up with industry trend. very good!
I am truly thankful to the holder of this website, because your idea is very good, and that is a trend in mold industry
Hi there, I check your blog on a regular basis. Your story-telling style is awesome, keep doing what you’re
doing!
I believe this requirement is from your customers, because they can decide everything
The human cost in China is becoming more and more expensive
no doubt! that will be a big investment, but it just depends on your market requirement
the idea from your company is very good! it will benefit your customers!
Pretty! This is an extremely professional ideal.and this is a trend
Investment in equipment to improve production efficiency is a good idea
that is a good news for me, I think it will improve your core competitiveness
Hello, you have luck to work in a company like this
also I really want to have an opportunity to work in a company like this
This is the trend of the development of our mould industry
For each mold company, technology is the first
you have luck to work in a company like this
I am so excited to read this article, because I am waiting for that day!
You painted a beautiful blueprint:-)
I agree your point, but it is not easy to completely come true
this is a trend in our mold industry! you got it
your company is on the right track
your thought is very good, I think this is a trend
I appreciate your idea,because it is not easy do this step
This article is very proactive, Automation is a trend in mold industry
first-rate mold company is our goal
As a senior mold engineer, I prefer to choose traditional mold manufacturing technology
as for this topic, I think maybe different mold company has different opinion
I think your investment direction is right
I am really pleased to read this weblog posts which carries
plenty of valuable information, thanks for providing these data.
Your idea is very advanced, this article increases my knowledge.
I think Automation is the developing trend in our mold industry
your ideal describes a beautiful future for us!
wow! we are still waiting for that day!
You are a pioneer in mold industry
Your idea is very advanced
In Russia, a lot of mould enterprises are far from automation
I learned some new ideal here, this articel is good!
Automation is a trend in our mold industry
this is a trend in our mold industry
first-rate mold company means first-rate mold solution co.,ltd, right?
our company is planning it
I am looking forward to our automation
I don’t agree with you, because real automation will take time
This is our mould industry development trend
this article expands my horizons
We still need to take a long time to achieve this goal, even if some mold companies achieved this goal
I think you are too optimistic
But it is also a huge investment
we are still waiting for that day, because Automation is not easy for a mold company
I think every mold company needs Automation, but sometimes I don’t think so. This is due to the particularity of mold production
as a professional mold maker, Automation is our goal
I still think the practical experience in mould design and manufacturing is the most important part
Mold enterprise needs to take a long time to achieve full automation
that means your company is in the forefront of the trend
Automation is the trend of the development of mould industry, unstoppable!!!
it will mean more and more peoples will leave our mould industry
This is a gradually realizing process
it seems to be a good thing for our mold industry, but actually we need to solve a lot of problems
Good equipments also need good employees
I think now our production conditions can meet our production requirements, Automation is our next step
Automation will be a revolution in our mold industry
our company is not first-rate mold company,We buy all our equipments just according to our employee’s ablity
Automation is a trend in mould industry.
I think the assembly of a mold still need workers
We are trying to become first-rate mold company:-)
as a senior mold engineer, in my opinion, This statement is not mature
We are more willing to believe that experience is more important, so that we can better exert the function of a new equipment
because every mould production process is a single-piece production process, so full automation is not easy to come ture
I also hope that our company can loudly say those words:-)
In Europe, the production in many mould companies has a high degree of automation
It’s amazing ideal for every mold maker, But the staff and funding costs also have to be considered
in that case, many peoples in mold industry will be out of work!
Thanks for sharing your thoughts about Automation.in mold industry, Automation is a trend. Regards
I clearly tell you, a lot of mould companies still cannot do it.
The best way is to combine experience and equipment,It is not enough to just have advanced equipment.
Automation will lead a lot of peoples out of work.
Hi I am glad to see your company have such advanced idea, as a mold maker, we should learn from your company
Automation is the trend for mold industry. also is the need of the market.
I don’t think you are joking, but this is a big goal
This is my first time to see such a conclusion, I mean it is not easy to come ture.
This article describes The trend of the mould development
I roughly calculated the total investment according to your ideas.Many companies can not meet your requirements
The development of cutting tool is also very important,especially for the special cutting tools. otherwise,Automation is meaningless
Automation is not easy to come ture for a mold company, because mold manufacturing is a very special process, maybe I can learn some ideal from this article
in order to make it come true, CAD/CAM technology is the key to success
you are luck! we are still waiting for the day:-)
I want to say this is just a trend, most companies are still on their original way. because it is not easy, too much need to match!
Hi I am glad to see your company to do like that, our company is planning. this is a trend, it is the demand of market
I am able to find good info from your articles. as for your point in this article, I think only few mold companies around the world can do it
at least for our local mold company,This topic is advanced,As a mould practitioner,I think Full Automation is not easy.Because some details still have to depend on manual work
Hi colleague! Automation is coming to first-rate mold company, that sounds good, but it requires money and corresponding engineers and skilled workers, not easy to come ture, Most of the mould companies around the world still maintain their original status
Yes! Our company is in this direction,Once come true, Our competitiveness will enhance a lot
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