Scott Phipps started in the mold making industry in 1978 and now owns United Tool and Mold (UTM), which operates from three locations in South Carolina and Alabama. UTM specializes in mold repair and has experience supporting molders globally. Phipps emphasizes the importance of communication, preventative maintenance planning, understanding the entire molding process, and paying attention to details when diagnosing and solving molding issues. He also discusses the challenges of finding skilled employees with diverse experience.

1. Are you fixing it right the second or third time?
Lessons in mold repair, preventative maintenance and people.
Scott Phipps
Owner
United Tool & Mold
Duncan location: (864) 859-8300
scott@utminc.com

2. The year was 1978. Scott Phipps started in the mold making trade
sweeping floors. Scott posses the ability to see problems as opportunities. Driven
with a strong work ethic that is fueled by passion Scott has advanced to now
owning his own group of companies: United Tool and Mold.
UTM was established in 1995 and currently operates from three
locations. Two are located in South Carolina and one in Alabama. UTM is unique in
the mold repair industry because of its global presence and overall approach to
problem solving. Successfully supporting the largest Tier I and II plastic injection
molders by working side by side with the largest shops in the USA, Canada
,Germany , Portugal, China, Japan and Korea. UTM has emerged as the go-to
resource in mold repair.
Scott feels he really started adding value to his customers when he
combined the knowledge of mold making, mold repair and process engineering.
Having this understanding helped him accurately determine root cause for most
plastic injection molding problems.
Scott Phipps, owner of UTM

3. Does this scenario sound familiar?
Your phone rings : It’s the molders Program
Manager, Process or Tooling Engineer. The
mold is not working and needs picked up
right now. Of course they owe parts
yesterday……
It could be one of many problems like flash,
manifold is “no good”, splay, gate blush part is
warping or cycle time cannot be achieved.
Nest step:
•Mold is shipped to your facility.
•Last shots included? If so marked up?
Documented action plan?
•Cost to expedite is not their problem since
the molder has classified this as ‘warranty’
repair.
Q: How can you diagnosis the real issues with
out a complete overview?
A: You cant. Nobody can.

4. It starts with communication:
•Technical problems can’t be solved
accurately and completely with
poor communication.
•Have you considered the entire
process when trouble shooting?
•Do you understand the principals
of the entire process?
•Having the most basic
understanding about the physics of
molding is key in solving the issues
that come up.

5. Building molds to budget:
Considering the right factors during the mold build budget planning
session will lead to success in production.
When cost outweighs performance and quality the resulting mold will
not have or be:
•The best mold for the application.
•A PM plan based on cycle counting.
•A clear understanding of the real cost accrued from not executing a PM
plan for the mold.
•The largest process window for production. * This is key to overcoming
environment and equipment variables during production.
•You will never know when your next major issue will overwhelm you. Its
like playing Russian roulette with injection molding.

6. Know what your jumping into:
Building molds with maintenance in mind from the beginning:
•Preventative maintenance planning and execution is the key to
keeping a mold capable and consistent for producing parts to
plan.
•Design the plan to minimize labor and fixed cost while
maximizing the return on investment.
•Capacity planning (labor hours and machinery) is critical if the
molder is serious about a PM plan. Do they have enough labor
and the right equipment to execute a real PM plan?
•The mold maker or mold repair company should be involved
upfront when the PM plan and ultimately the budget is set.
•All to often involving them is an after thought that results in
cost limitations for the PM plan. Ultimately compromising the
completeness of the PM plan.

7. Process monitoring:
Once the mold is built and the PPAP process is
established you have a baseline, It’s the target for
repairs. The images on the right are:
•The result of an operator increasing the shot volume
because short shots were occurring, They then walked
away for 30 minutes.
•Initially blame was put on the mold maker for
installing the manifold system incorrectly. This was
incorrect.
•The teams came together to solve the problem and
all agreed on the root cause diagnosis.
•The root cause: Press barrel was out of alignment to
the mold by 5mm or more. Preventing the correct seal
off that resulted in a leak.
•The end goal: Produce quality parts consistently over
time within the budgeted plan.

8. The devil is in the details:
Paying attention to details will go a long way
when trying to determine root cause of a
molding issue.
•Don’t assume anything.
•Verify the information you are being given
before using it to trouble shoot.
•Employ the “Stop and Fix” mentality:
•This is a balance of production demand
and time available for the repair.
•A interim repair.
•A complete repair plan and then the
executing that plan.
•One of the hardest things to do is go
back and fix while in the day to day
battle.
Direct gated part:
•B side is missing dimple.
•Result: Thin wall to thick wall flow.

9. The path to root cause analysis:
What are your tools?
1. The PPAP approved process setup
sheet.
2. The process control system of the
press.
3. The material data sheet.
4. Marked up parts from last run.
• Retain a full shot.
5. The Hot Runner Manifold controller
(diagnostic capable is important).
6. Resin or other supplier expertise.
7. Mold repair/Mold Making/Mold design
expertise.
8. Thermal imaging.
9. Experience, collaboration, teamwork.

10. Where will they come from?
How will you fill and retain the
increasing demand for employee’s with
diverse skills?
1. The need for skilled labor’s
demand is increasing.
2. Finding someone with experience
that has worked in multiple
disciplines is becoming tougher
and tougher.
3. Training: Internal and external.
1. Training on your own is increasing
in popularity.
2. Companies like Toolingdocs.com
and Tool Stats can train your team
for you: onsite or at their facility.
4. Teach common sense…..

11. United Tool & Mold
scott@utminc.com
(864) 859-8300
ROI Rich Oles Industries, LLC
richoles@gmail.com
(616) 610-7050
Check out the “Pellet 2 Part” series in Mold Making Technology magazine.

12. Thank you!
Leaders are visionaries with a poorly developed sense of fear, and no concept of the
odds against them. They make the impossible happen."
- Robert Koffler Jarvik