Transcript 725960 In-Mold Assembly

UNDERSTANDING THE USES AND BENEFITS OF
IN-MOLD TECHNOLOGY AND AUTOMATED
MANUFACTURING CELLS
Presented By:
Wade Clark, President/CEO
An Industry Leader.
•
•
•
•
•
Founded in 1988 with the focus on conventional EDM for the aviation and moldmaking
industry.
Built first mold in 1990.
Built first tool with In-Mold technology in 1995.
Built first tool with 3 individual molded assembled parts in 2001.
Electroform manufacturing has been automating and palletizing over ten years.
Research &
Development
•
•
•
•
Electroform has made a considerable
investment in Research &
Development of in-mold and
automated
technologies.
Clients come to us with complex
projects.
We assist on part design, product
development.
Supply turn-key automated work cells.
In-Mold Assembly
Combination of two or more parts to
make an assembly inside the
injection mold, without the need of
external automation.
•
Snapped
•
Riveted
•
Inserted
Types of assembly methods
•
Screwed
•
Pressed
•
Bonded
Combined with Other
Processes to Create Final
Component/Product.
Some of these processes are:
•
Stamped
•
Coined
•
Detached
•
Decorated
•
Closed
Advantages of In-Mold
Assembly and Automated
Manufacturing cells
•
Better fit and performance.
•
More consistent product
•
Not subject to warp and shrinkage issues
•
It enables you to find problems at the machine
or cell not later in manufacturing process
•
Part orientation (for In-Mold printing or
decoration or assembly)
•
Elimination of quality issues
•
Saves on handling, inventory and logistics
Other advantages
•
•
•
•
Creating a sub-assembly
Preparation for downstream process
Protection for part handling
Eliminate contamination
Choosing a Supplier
•
•
•
•
•
•
•
Get supplier involved early in the development process
Does your supplier have processing capabilities?
Is your supplier capable of in-house training and support?
Does your supplier offer an assembly and preventative
maintenance manual?
Choose a supplier that has a good understanding of each
part of the process.
Do you trust your supplier?
Does your supplier offer a comparison of standard
automation vs. in-mold assembly?
Prototype First
•
Make sure you choose right
materials for the application
•
Prove capability and
functionality
•
Molds and automation can be
very complex.
•
Cost can be substantial once
process started.
Highlights from
NPE:
In-Mold Components
The process…
has it changed?
Traditional Process:
In-Mold Process:
Case Study
In-Mold Assembly
One Two-Shot Press with Robot: $285,000
One Mold: $213,310
System to Present the Film: $40,000
Total: $538,310
Traditional Molded and Assembled Product
Three Separate Molds: $210,960
Three Presses one with Automation: $285,000
Automation to Present the Film: $40,000
Automation to Assembly the Car: $190,000
Total: $725,960
Capital Savings with the In-Mold Process:
$187,650
Case Study
Injection Molded Piece Part Costs Without Film
(Based on four million finished cars per year)
Press rate of: $70.00 per hour for 250 2-Ton Shot Machine
With .125 Operator at $25.00 per hour
Cycle Time: 15 seconds
Cost: $.126
Press rate of $50.00 per hour each for 80-ton Molding Machines
With .333 Operator at $25.00 per hour
Cycle Time: 10 seconds per mold
Cost: $.172 (cost does not include assembly)
Total Cost Savings of In-Mold Assembly:
$184,000 per year
Initiate Ideas!
Ideas must be right,
up front…
Accept ability to
adapt!
Formation of a…
Training leads to…
KEYS TO SUCCESS
Manufacturing
Automation
Automation
to remove labor and improve production
See what you can do!