Management, repair, and maintenance of the Mold Industry
In recent years, customer orders and industrial demands have been diverse. Coupled with the impact of the epidemic, changes in orders are more difficult to grasp. What the manufacturing industry can control itself is all kinds of internal management. Good management, to be able to respond to changes at any time.
Molds are important to the plastic injection industry. There may be hundreds or thousands of molds in a factory. To ensure product quality, molds in good condition must be used. To grasp the mold status at any time, how to carry out mold management systematically? You can use the mold common mode mechanism and the mold management process to systematically grasp the mold information to achieve the purpose of mold management. Mold management needs to master the mold information, to quickly achieve the correct production schedule planning, and to quickly face the temporary demand changes of the industry or customers.
Molds are important to the plastic injection industry. There may be hundreds or thousands of molds in a factory. To ensure product quality, molds in good condition must be used. To grasp the mold status at any time, how to carry out mold management systematically? You can use the mold common mode mechanism and the mold management process to systematically grasp the mold information to achieve the purpose of mold management. Mold management needs to master the mold information, to quickly achieve the correct production schedule planning, and to quickly face the temporary demand changes of the industry or customers.
Importance of mold:
Mold is the most important part of plastic injection. The cost of the plastic injection industry, in addition to equipment, should be the most expensive mold. The cost of the mold can range from hundreds of thousands to millions, so it is important to extend the service life of the mold. Before the production schedule, it is necessary to confirm the tonnage of the injection machine, the condition of the mold, the material formula, the peripheral equipment (such as the drying machine), and other conditions, to make the production schedule well and reduce the frequency of mold change and line change. Reduce workflow waste.
The higher the health of the mold, the better the quality of the products produced, the higher the yield, and the longer the service life of the mold. Therefore, without the use of healthy molds, it is of course impossible to produce high-quality products. Molds require regular maintenance to maintain a healthy state. If the damage during use can be reduced, the service life of the mold can be extended. After the mold is used a certain number of times (mold times), it will affect the health and usage of the mold, so it needs regular maintenance and repair.
The higher the health of the mold, the better the quality of the products produced, the higher the yield, and the longer the service life of the mold. Therefore, without the use of healthy molds, it is of course impossible to produce high-quality products. Molds require regular maintenance to maintain a healthy state. If the damage during use can be reduced, the service life of the mold can be extended. After the mold is used a certain number of times (mold times), it will affect the health and usage of the mold, so it needs regular maintenance and repair.
Common problems with molds:
However, it often happens during production. The injection-related machines, materials, and personnel are ready, but after the mold is loaded, it is found that the mold is not oiled and rusted or the parts are loose, and the mold must be removed from the equipment. Or it has been found that there is a quality problem during the production process. After various inspections, it was found that the mold had wear problems. If mold maintenance is required at this time, it will take several days of maintenance time and will not be able to produce, which will affect the arranged production plan and fail to operate as scheduled. The delivery date of the order originally replied to the customer could not be shipped as scheduled. The equipment machines are therefore shut down, resulting in a decrease in the utilization rate and utilization rate, as well as waste of materials and labor costs.
Before production scheduling, you need to confirm the mold status information:
Before the production schedule, it is necessary to confirm the status of many molds, such as confirming the status of the molds, is it common mode. Use the confirmation of the number of mold cavities and healthy cavities to convert the number of finished products per shot.
Before production scheduling, you need to confirm the mold status information:
Before the production schedule, it is necessary to confirm the status of many molds, such as confirming the status of the molds, is it common mode. Use the confirmation of the number of mold cavities and healthy cavities to convert the number of finished products per shot.
What are the important data and information about the mold?
Once an urgent order is received, it can be produced immediately. It will not be necessary to repair or maintain the mold because of unhealthy or defective molds, which will cause the production schedule to fail and become a production bottleneck. The health of the mold greatly affects the quality of plastic injection. Therefore, mold management should be done in ordinary times. Keeping abreast of the mold status and important data information on the mold can make the production schedule accurate, or facilitate the temporary adjustment of the production schedule.
Mode status:
Does the mold need maintenance? The most basic reference is the number of times the mold is used.
Mold common mode status:
Are there products of different product numbers, but use the same mold?
Mold replacement status:
For products of different product numbers, due to the adjustment of the style, it is necessary to change the design of the mold core and change the mold. Has the mold been repaired? What is the status of the mold repair? Is there a corresponding product number that needs to be adjusted accordingly?
Cavity change status:
Is the mold damaged and unusable, and needs to be replaced? Has the replacement been completed?
The number of healthy points:
After the mold is used, there will be damage. For a mold with multiple cavities, how many cavities can be used for health? Which cavities are worn out? In future production, the mold cavity should be avoided for production, to avoid the production of defective products. At that time, the quality control personnel will also need to pick out the defective products.
Digital software system tools can help factories collect important mold-related data and information, allowing factories to use digital transformation, industry 4.0, and smart manufacturing technologies and methods to make factories more digital and smart.
Mode status:
Does the mold need maintenance? The most basic reference is the number of times the mold is used.
Mold common mode status:
Are there products of different product numbers, but use the same mold?
Mold replacement status:
For products of different product numbers, due to the adjustment of the style, it is necessary to change the design of the mold core and change the mold. Has the mold been repaired? What is the status of the mold repair? Is there a corresponding product number that needs to be adjusted accordingly?
Cavity change status:
Is the mold damaged and unusable, and needs to be replaced? Has the replacement been completed?
The number of healthy points:
After the mold is used, there will be damage. For a mold with multiple cavities, how many cavities can be used for health? Which cavities are worn out? In future production, the mold cavity should be avoided for production, to avoid the production of defective products. At that time, the quality control personnel will also need to pick out the defective products.
Digital software system tools can help factories collect important mold-related data and information, allowing factories to use digital transformation, industry 4.0, and smart manufacturing technologies and methods to make factories more digital and smart.
Mold-related management items:
Mold common mode mechanism:
Solve the quantity control of one-mode multi-cavity and common mode in production.
Solve the quantity control of one-mode multi-cavity and common mode in production.
- Mold product number control management: A set of molds often includes male molds, female molds, mold cores, etc. The arrangement and combination of different structures, corresponding to different product numbers, need to be recorded and managed.
- Mold common mode management: Molds often have multiple cavities or common molds, but the usage, damage, and health of each cavity are different and must be recorded in detail as an important basis for estimating mold output during production scheduling.
Mold management process:
Each time the mold is used, mold inspection, production and return to storage, etc., the status of different stages are recorded. What is the status of the mold inspection? After production, when the mold is put into storage, it is necessary to confirm the production record of the mold. Including the number of holes in the mold and the number of production times of each hole, as the basis for follow-up maintenance.
If the information in the mold management process can be recorded in a complete, real, and real-time manner, the current status of the mold can be quickly grasped. Digital software system tools can assist the manufacturing industry in quickly completing information records. In addition to accurately arranging the production plan, the mold can be maintained or repaired according to the warranty plan to maintain the health and availability of the mold to ensure product quality and prolong the life of the mold.
- Mold condition management: The current state of the mold is in the warehouse, where is it in the warehouse? Or in use, by what order? Are the molds returned? Wait, the current state of the mold is displayed.
- Model management: Management of mold production and use times, mold production quality status records, etc.
- Maintenance management: If the production quality is abnormal when the mold is in use, it needs to be repaired. If you ask an external manufacturer to repair it, what is the status of the repair? When will the repairs be completed and have they been put into storage?
- Maintenance plan: Plan maintenance schedules. After the mold has been used for a certain number of times, a certain period, or under other specific standards. It is necessary to carry out regular inspection records and maintenance to ensure that the proper rate and availability of the mold can be maintained above a certain standard at any time.
- Mold resume: You can see what happens to the mold in its entire life cycle. It integrates the condition of molds, mold records, maintenance records, and maintenance records.
- Mould Records: What has the mold ever been through? For example, the mold is composed of those male molds, the combination of female molds and mold cores, the state of mold trial, and what machine has been used to produce them.
- Mold record: Plan the life and aging of the mold, and display the current stage status according to the mold production record.
- Maintenance records: Statistical records of mold maintenance in the past, what maintenance items have been done? Which external manufacturer is invited to carry out the maintenance? What is the repair status? Which parts have been replaced?
- Maintenance records: Regular time maintenance reminders for molds, records of elimination and replacement of parts and accessories, etc.
If the information in the mold management process can be recorded in a complete, real, and real-time manner, the current status of the mold can be quickly grasped. Digital software system tools can assist the manufacturing industry in quickly completing information records. In addition to accurately arranging the production plan, the mold can be maintained or repaired according to the warranty plan to maintain the health and availability of the mold to ensure product quality and prolong the life of the mold.
How to quickly grasp the status of each mold in the factory? We can think about using modern technology tools, such as automated reporting tools and systems, to assist the staff in the simplest way to digitize the status information of the molds, to help grasp the current status of each mold at any time. After the mold information is digitized, key reminder points can be set in the production execution management system. Mold cleaning, repair, and maintenance are performed at time points that do not affect production to maintain mold health and extend mold life. Only by ensuring the proper rate of molds at any time can the equipment utilization rate be increased, so that the molds can ensure the effective operation of the overall production capacity at important production moments.
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