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Reduced labor costs and time to market have become important issues in the injection molding industry. Increased competition has caused injection molding shops to find ways to reduce production runs, high inventory levels and extended mold change times. The answer is quick-mold change solutions from Hilma by Carr Lane Roemheld.

 

Normal Mold Change time
Quick Mold Change time

 

Why Quick Mold Change?

To survive in today’s competitive, worldwide market, manufacturers are reducing inventory cost by running smaller batch sizes and making shorter production runs. One way to maximize press uptime in an environment like this is to implement faster, more effective mold changes. That’s where Carr Lane Roemheld, a leading Quick mold change system manufacturer comes in.

A quick mold change means that the material for the next part is in place, automation is set-up and the mold is located and clamped in position. With Quick-Mold change system, the mold is clamped in the same place, the same way, every time. Because of this, mold changes are accomplished in the shortest time possible.

When Quick Mold Change (QMC) is implemented, companies will enjoy the benefits of:
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  • Reduced Inventories, due to smaller quantities runs and more frequent changeovers.
  • Increased Machine Capacity, by improving production and its product revenue.
  • Improved Lead Times, due to quick change overs.
  • More Competitive, through just-in-time deliveries and better service to customers.
  • Improved Quality of parts, due to repeatable positioning and clamping forces.
  • Reduced Labor Costs, mold changes can often be done by the operator in a fraction of the previous time.
  • Improved Safety, the molds are under control and roll smoothly in and out of the injection mold machine during the mold change, and with automated systems, if the mold is not clamped properly, the injection molding machine simply will not operate.

 

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How to Get Started with Quick Mold Change 

Step 1. Create a Quick Mold Change Team
Step 2. Select and Analyze a Machine and Its Molds
Step 3. Analyze the Present Mold Change Process
Step 4. Research and Implement the New Processes and Standards
Step 5. Evaluate the New Process
Step 6. Follow-Up and Repeat the Process


Step 1
Create a Quick Mold Change Team

Select a team and appoint a team leader

Upper Management Injection Molding Machine Operator
Manufacturing Engineer Set-Up Personnel
Tooling Engineer Maintenance Supervisor
Production Supervisor Accountant

Step 2
Select and Analyze a Quick Mold Change Machine and Its Molds

Each QMC application is different. There is no single method that is best for all applications. The most appropriate method to be used for each machine is determined by carefully examining all production requirements and related data. The following is some of the information that needs to be reviewed before selecting a QMC machine:

  • What are the present and long range production requirements?
  • What is the goal for mold change time?
  • How is the plant layout?
  • Which machines are involved?
  • How many molds are used in the machine?
  • Minimum and maximum sizes and weights of molds.
  • Present clamping method; the quantity and size of the bolts used.
  • Clamping points: locations, shape, clamping heights, depth of ledge.


Step 3
Analyze the Present Mold Change Process

First, carefully review your present method of mold changeover. You must know where you are now to decide what steps are needed to achieve your goals.

 

  1. Analyze every step and the sequence required to make a mold change.
  2. Break down each step in the mold process to help determine how it can be reduced or eliminated.
  3. How much time is required for each step? To get accurate times, casually observe a set-up team on several occasions. Obviously an authority figure standing near the machine with a watch or a video camera will produce figures less than the actual times occuring day to day.
  4. Who is involved in the mold change process?
  5. What is required? What tools? What materials?


Step 4
Research and Implement the New Mold Change Process and Standards

After the present mold change process has been analyzed, look for ways to improve the process. The objective is to minimize the steps required and not to duplicate your work. Develop ways that will make changing a molds easier and faster.

Start with things that are simple and low cost:
Have new mold(s) prepared and staged in advance near the machines.
Mold storage areas should be located near press.
Minimize raw material handling.
Have clamps and tools prepared before the machine shuts down for the mold change.

Standardization must be evaluated to achieve your Quick Mold Change goals. The variety and sizes of molds that have been accumulating in plants everywhere make changeovers time consuming and tedious, since standardization was not a consideration when the molds were designed and built.


Step 5
Evaluate the New Process


Step 6
Follow-Up and Repeat the Process

Quick Mold Change Applications

 

 

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