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Maximizing Machine Productivity - Your Trending Need (By: Nitin Chowdhary)
- 1. Maximizing Machine Productivity - Your Trending Need
- 3. OUR CUSTOMERS • ELECTRICALS • MEDICAL • PET PREFORMS • AUTOMOTIVE • 2 WHEELER AUTOMOTIVES• INDUSTRIAL WHITE GOODS HOUSE HOLD FURNITURE
- 4. OUR CUSTOMERS • CPVC PIPES • RPVC / UPVC PIPES • HDPE / PP / PPR PIPES • ROUND DRIP • IRRIGATION LINE • CORRUGATED PIPE • FOOD GRAIN & ATTA PACKS • FLEXIBLE PACKAGING • SNACK FOOD PACKS SHRINK PACK PEELABLE FILMS TARPAULINDAIRY PRODUCT PACKS
- 5. CUSTOMER SERVICE & SPARES WIN CUSTOMER SERVICES & SPARES Preventive Maintenance Contract Breakdown Services Spare Centers Expert Service Engineers Retrofitment Center Expert Service Engineers
- 6. Maximizing Machine Productivity - Your Trending Need
- 8. INJECTION MOULDING - PROCESS PLASTICS ENTERS FACTORY STORAGE MATERIAL CONDITIONING MOULD MANAGEMENT MOULDING PROCESS PART HANDLING POST MOULDING PACKAGING SHIPPING
- 9. FACTORS IMPACTING PRODUCTIVITY PART DESIGN MOULD DESIGN & BUILD MATERIAL SELECTION MOULDING MACHINE MOULDING PROCESS DATA CAPTURING & ANALYTICS [ AI ] AUTOMATION & ROBOTICS IMPROVING PRODUCTIVITY BY 10% OR MORE
- 10. PART & MOULD DESIGN PART DESIGN MOULD DESIGN & BUILD ASSUMING OPTIMUM PART DESIGN & MOULD
- 11. MOULDING MACHINE MOULDING MACHINE MACHINE SPECIFICATION FOR THE PART IS CRITICAL
- 12. MATERIAL SCIENCE & TECHNOLOGY MATERIAL SELECTION Amorphous Semi - Crystalline High Performance Polymers Mid-Range Polymers Common Polymers PS SAN PVC LDPE HDPE PP PE-UHMW POM PBT PET PA-6/6,6 PA-4,6 PPA PPS LCP PVDF FP PEEK PI PAI TPI PPSU PEI PES PSF PAR PPC PC PPO SMA ABS PMMA ABS-acrylonitrile butadiene styrene FP-fluoropolymers HDPE-high density polyethylene LCP-liquid crystal polymers LDPE-low density polyethylene PA 4,6-polyamide 4,6 PA 6/6,6-polyamide 6/6,6 PAI-polyamide imide PAR-polyarylate PBT-polybutylene terephthalate PC-polycarbonate PE UHMW-ultrahigh mol. weight PE PEEK-polyetheretherketone PEI-polyether imide PES-polyethersulfome PET-polyethylene terephthalate PI-polyimide PMMA-polymethyl methacrylate POM-polyoxymethylene PP-polypropylene PPA-polyphtalamide PPC-polyphthalate carbonate PPO-polyphenylene oxide PPS-polyphenylene sulfide PPSU-polyphenylsulfone PS-polystyrene PSF-polysulfone PVC-polyvinyl chloride PVDF-polyvinylidene fluoride SAN styrene acrylonitrile SMA-styrene maleic anhydride TPI-thermoplastic polyimide
- 13. PREDICTED PERFORMANCE AUTOMATION & ROBOTICS Manual 1** Manual 2** Robot 1 Robot 2 Injection & Cooling 40 15 40 15 Mould open 1,2* 1,2* 0,8* 0,8* Gate open 1 1 - - Take out 2 2 1 1 Gate close & Restart 1,5 1,5 - - Mould close 1,2* 1,2* 0,8* 0,8* Total Cycle 46,9 21,9 42,6 17,6 Saving 1 9,2% Saving 2 19,6% *) Mould open stroke is normally longer for manual take out operation **) In case of parts dropping there is mostly an Increase of cycle time ! Robot Automation – Cycle Times
- 14. MEASURE, ANALYZE & IMPROVE DATA CAPTURING & ANALYTICS [ AI ] We have implemented SAM4.0 across 400+ injection machines & 15+ extrusion machines below are some of the examples of impact of SAM4.0 - OEE improvement analyze - Energy per Kg – down - Reduced downtime - Improved quality - Man hours saved on manually crunching the data in required format - Authenticity of data from machine to management
- 15. MOULDING PROCESS TECHNOLOGY MOULDING PROCESS SCIENTIFIC MOULDING – JOHN BOZZELLI KEY DATA PLOTTING FOR OPTIMUM PROCESS SETTING 1. Aesthetic Process Window 2. Dimensional Process Window 3. Control Process Window Scientific molding is a machine-independent process that provides certain basic parameters to optimize the molding process. Key Parameters among them are: 1. Plastics temperature 2. Plastics pressure 3. Velocity of injection 4. Cooling
- 16. TAKING THE THEORY FOR A “SPIN” Case Studies: 18 Materials: PP, PA, PBT, PVC, ABS Applications: Household, Furniture, Paint Pail, Cosmetics, Writing Instruments, White Goods, Automotive Productivity Improvement: Cycle Time Reduction by 9% to a maximum of 33%, depending on the application and the raw material used. IMPROVED PRODUCTIVITY BY 10% OR MORE
- 17. TAKING THE THEORY FOR A “SPIN” Product Details RawMaterial Machine Tonnage Cycle Times (Sec.) Cycle Time Reduction Per Hour Parts Produced Increase In Machine Productivity Name TotalShot Wt.(g) No.Of Cavities Before After Sec. % Before After # of Parts % Container 14 4 PP 200 15.5 12.5 3 19% 929 1152 223 24% Houseware 448 8 PP 450 30 24 6 20% 960 1200 240 25% Tray 370 1 PP 350 37.5 32.4 5.1 13% 96 111 15 16% Brush Handle 474 12 PP 450 43.4 33.8 9.6 22% 995 1278 283 28% 18L Pail 735.5 1 PP 450 32.5 29 3.5 11% 111 124 13 12% Refrg. Part 55 4 PP 130 39.6 29.7 9.9 25% 364 485 121 33% Application: Household & White Goods
- 18. TAKING THE THEORY FOR A “SPIN” Product Details RawMaterial Machine Tonnage Cycle Times (Sec.) Cycle Time Reduction Per Hour Parts Produced Increase In Machine Productivity Name TotalShot Wt.(g) No.Of Cavities Before After Sec. % Before After # of Parts % Pen Barrel 48 16 PP 85 36 28.8 7.2 20 1600 2000 400 25% Pen Cap 51 32 PP 85 28.3 21.3 7 23 4071 5408 1337 33% Application: Pen Barrel & Pen Cap
- 19. TAKING THE THEORY FOR A “SPIN” Product Details RawMaterial Machine Tonnage Cycle Times (Sec.) Cycle Time Reduction Per Hour Parts Produced Increase In Machine Productivity Name TotalShot Wt.(g) No.Of Cavities Before After Sec. % Before After # of Parts % Electrical Housing 36 4 PBT (20% GF) 150 30 24 6 20 480 600 120 25% Application: Electrical
- 20. TAKING THE THEORY FOR A “SPIN” Product Details RawMaterial Machine Tonnage Cycle Times (Sec.) Cycle Time Reduction Per Hour Parts Produced Increase In Machine Productivity Name TotalShot Wt.(g) No.Of Cavities Before After Sec. % Before After # of Parts % Wide Bottle Cap 24.5 4 PP 150 18.8 15.8 3 16% 766 911 145 19% Cosmetic Cap 50 16 PP 150 27.6 21.7 5.9 21% 2087 2654 567 27% Application: Other Caps & Closures
- 21. TAKING THE THEORY FOR A “SPIN” Product Details RawMaterial Machine Tonnage Cycle Times (Sec.) Cycle Time Reduction Per Hour Parts Produced Increase In Machine Productivity Name TotalShot Wt.(g) No.Of Cavities Before After Sec. % Before After # of Parts % Auto Component -- 2 Nylon (30% GF) 130 60 40 20 33% 120 180 60 50% Auto Component -- 2 Nylon (30% GF) 85 71.6 56.6 15 21% 101 127 26 26% Auto Component -- 2 Nylon 6 50 19.5 13 6.5 33% 369 554 185 50% Auto Component -- 1 PVC Comp. 150 85 65 20 23% 42 55 13 31% Application: 2 Wheeler Auto Component
- 22. TAKING THE THEORY FOR A “SPIN” Product Details RawMaterial Machine Tonnage Cycle Times (Sec.) Cycle Time Reduction Per Hour Parts Produced Increase In Machine Productivity Name TotalShot Wt.(g) No.Of Cavities Before After Sec. % Before After # of Parts % Auto Component 850 1 PP (40% GF) 1500 65.4 49.4 16 24% 55 73 18 33% Auto Component 1500 1 PP (Talc) 1500 57.5 52.5 5 9%* 63 69 6 10%* Application: 4 Wheeler Auto Component * Main objective was reduction of high part rejections… Part rejections was brought down to “Zero” along with productivity improvement (pending actions)
- 23. PART & CUSTOMER QUALIFICATION 2 Key Qualifying Factors: 1. The Moulding environment should be under capacity constraint. There is no need for such a work to be conducted when the plant capacity is under utilised. It makes no sense to get additional machine capacity through productivity when you already have idle machine capacity. 2. The Moulding environment should be fighting for quality improvement and troubleshooting for decreasing rejection rates. If you do not have a part with critical dimensional requirements and / or do not feel the need to save money by reducing rejection rates then again there is no need to employ any scientific process improvements and invest in technological advancements.
- 24. THANK YOU Q & A