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Improving metal mechanics cluster capabilities in the State of Chihuahua (Die & Mold)
2014 KSP with Mexico
Su-Jin Kim
Dep. of Mechanical Engineering
Gyeongsang National University
Final Reporting Workshop
May 14th 2015, Mexico city
Introduction
Background and Objectives
3
Background: Die/Mold & tooling imports reached $2,630 million in 2012
1) The inability to produce Die & Mold creates dependency on producers and often
limits the performance of the advanced local manufacturing capacities.
Objective : This project seeks to improve three main challenges of the metal mechanics
sectors related to the die and mold processes.
1) Benchmarking training and education program for the technical schools
2) Strategic formulation of government policies to develop Die & Mold sector
3) Connecting local SMEs and Korean enterprises
Chihuahua Institute of Technology
4
1) Chihuahua institute of technological has department of mechanical engineering.
2) The school offers master’s level course in mechanical and electrical engineering in the field
of graphic research and robotics.
3) The students are qualified to become a process analysis engineer.
Training and Education
Technological University
1) The university is a training ground for students aspiring to become a technician and
provides two-year training programs.
2) The university is equipped with necessary equipments for trainings such as milling, CNC
milling, grinding machine, sink electric discharge machine, plastic injection machine and
has faculty members who have experience in industry as well as training students.
3) The university will benefit from a mold education program from Korea Polytechnics if it is
able to employ professors on sabbatical leave.
CENALTEC
5
1) CENALTEC trains manual assembly process to the newly recruited workers in 20 aircraft
industries.
2) Best equipment: The center boasts 10 CNC milling(HASS, MAKINO), 10 turning center, wire
electric discharge machine, CAD/CAM software(NX), and two plastic injection machine
required for mold processing.
3) Poor mold technology: Two basic mold-producing rectangular plastic boxes have been
developed through joint collaboration. The standard mold base set was imported from the
US of which the delivery took two months. There are concerns as to whether shrinkage or
deformation might occur during the injection process.
4) Open to mold business: If Korean mold design engineers do business on equipments, local
plastic companies will be able to develop automotive part and supply to OEM enterprise
which will trigger technological transfer to CENALTC.
Training and Education
Visited International Enterprise in Chihuahua city
6
Mold Industry
1) Big enterprises assemble plastic and metal parts to the module of Automotive and Home
appliance.
2) Die and mold are imported from Asia or USA rather than local mold producers.
3) Used molds are repaired in a small tool room within the enterprise.
4) Pace industries (die casting), TRW automotive (steering wheel), Manesa (press)
Visited Local SMEs in Chihuahua city
7
Mold Industry
1) Sheet metal stamping: Prototype in FabLab, Mass production with progressive die (Strong)
2) Plastic & aluminum molding: 1 mold maker, 1 mold repair, 3 NC machining
3) The Mold repair is a thriving business in Chihuahua. There are hundreds of plastic injection
machines and ten die casting machines. Mold must be repaired in a week. (Strong)
4) The mold producers were unable to supply to international companies due to higher price
compared to China. (Weak)
5) CADISA(Progressive Die), PALOMINO(Machining), HASI(Mold repairing), CBQ
Technology(Rubber mold), Altaser Aerospace(5x Machining), Plasti-contemedores(Mold
maker)
Mold SMEs in Mexico (2013)
8
1) Visited Die & Mold companies at Queretaro, Saltillo and Monterrey in 2013.
2) Mexican die & mold companies focused on repairing. They showed weakness in design and
machining of new mold, due to high price, slow delivery, and underdeveloped technology
compared to imported mold. In contrast their forte was in maintenance & repair activities
on broken mold that required prompt service.
3) Korean die & mold companies showed considerable strength in price, delivery time, and
quality, but were weak at maintenance services due to long distance. Symbiotic relationship
may arise if Korean die & mold producers export to Mexican partners and Mexican partners
maintain the mold.
Mold Industry
What is Die & Mold?
10
1) Die & Mold is a tool used to produce large quantities of same products.
2) Automobile, television and home appliances are produced by large quantities of Die & Mold.
Blow Mold Diecasting Mold
Press Die Forging Die Plastic injection Mold
Korean war, LG chemical, TaeguTec, 1st Die & Mold companies started business
60 years of Korean Die & Mold
11
1960s
Milling & lathe (whacheon.com), Injection molding machine(dongsin)
Electric discharge machining, Standard moldmase, Die & Mold training school (Polytechnic II)
NC machine tools, Korea Die & Mold Industry Cooperative (KODMIC)
CAD/CAM & CNC, Wire EDM , Tungsten carbide tool, Die steel
Export $210million > import $190 million in 1994
Huge mold for automobile, Precision mold for electronics,
1,379 die/mold companies. Export $3,228 million >> Import $158 million in 2014
1970s
1980s
1990s
2000s
ⓒ 30 years history of KODMIC
1950s
ⓒ www.koreamold.com
20 years Export & Import
12
1) The exports $210 million exceeded the imports $190 million first in 1994.
2) The export is increasing 16% every year from 2009.
3) Korea exported $3,228 million in die & mold and imported $158 million a year 2014.
123 210
616
1,223 1,452
1766
2,248 2,512
2,676
3,228
139 190 68 151 140 135 140 152 164 158
0
500
1000
1500
2000
2500
3000
3500
1990 1994 2000 2005 2009 2010 2011 2012 2013 2014
Export
Import
million $
year
Die & Mold Companies of Korea
13
1) There are around 1,379 Die & Mold companies (over 10 employees) in Korea (2012).
2) 53% of companies are located around Seoul-Incheon. 21% around Busan.
3) The total employees are 36,832 and the average number of employees in a company is 27.
53.3% Companies are
locating nearby Seoul Gyeonggi
81 (5.9%)
32 (2.4%)
20 (1.4%)
509 (36.8%)
289 (20.9%)
202 (14.5%)
20 (1.4%)
85 (6.1%)
Incheon
Seoul
Daejeon
Chungnam
Chunngbuk
Daegu
Gyeongbuk
Busan
Ulsan
Gyeongnam
Jeonbuk
Gwangju
Jeonnam
Gangwon
2 (0.1%)
145 (10.5%)
ⓒ www.koreamold.com
Die & Mold Companies of Korea
14
1) The total production volume was $7,086 million in 2012 based on the companies with 10 or
more employees.
2) The portion of plastic mold and press die is 75.2%. The production volume of plastic molds
is $2,948 million and press die is $2,385 million.
3) The average growth rate was 9.5% during 2009 to 2012
Plastic
Molds, 2,948
Press Dies,
2,385
Diecasting
Molds, 129
Other, 888
Standard
Parts, 740
Total $7,086 million in 2012
ⓒ www.koreamold.com
ⓒ www.koreamold.com
Export of Korean Die & Mold
15
1) Korea exports about 37% of its total die and mold production.
2) The export volume ratio is about 63% in Asia and about 7% in Mexico.
Japan 17% China 17%
India 9% Mexico 7%
USA 7%
Malaysia 4%
Indonesia 3%
Vietnam 5%
Brazil 3%
Russia 3%
Turkey 3%
ⓒ www.koreamold.com
World’s Mold Export and Import
16
1) Korea was the world’s second largest die and mold exporting country in 2014
2) Export: China 4,926 > Korea 3,228 > Japan 2,908 > Germany 2,553 > USA 1,431 (2014)
3) Mexico imported $2,630 million in die & mold and tools (2012).
4) Import : USA 3,093 > Mexico 2,630 > China 2,599 (2012, 2013)
0
500
1,000
1,500
2,000
2,500
3,000
3,500
4,000
4,500
China Korea Japan Germany USA
million $ Export
0
500
1,000
1,500
2,000
2,500
3,000
3,500
4,000
4,500
USA Mexico China
million Import
Demand Industries of Die & Mold
17
1) Korea Die & Mold companies increased with the automobile and electronics industries
using molds for mass production.
※ Source : Survey on Mold Industry Status, Korea Die & Mold Industry Cooperative, 2012
Semiconductor
Office
Supplies
Household
Item Others
Automobile
Home
Appliance
IT Device
Supporting Industries of Die & Mold
18
CAD/CAM Precise Machining Production
asis.co.kr
NC Machining hwacheon.com
Simulation NCBrain.com
EDM kojin.co.kr
Noldbase Kishin.com
endmill taegutec.co.kr
Press simpac.co.kr
Injection dongshin.net
Plastic lgchem.com
Sheet metal posco.co.kr
1) The machine tools and material technologies supporting die and mold are well developed.
Korea Polytechnic II
19
1) Department of die & mold opened in 1974 and offers 2 years program.
2) 90 students design and fabricate die & mold to graduate.
incheon.kopo.ac.kr
Korea Polytechnic II
20
1) The education programs : 60% technology training + 40% lecture.
2) Training and education program of the Chihuahua technological school will benchmark the
Department of Die & Mold Design in “Korea Polytechnic II”.
Semester Lecture Practice
1st Injection mold
Stamping die
Precise metrology
Mold drafting
NC machining
Basic machining
NC machining
3d Modeling
CAD practice
2nd Mold manufacturing
Mold material
Product design & post process
Mold develop project1
CAM practice
Precise part machining
3rd Precise mold design
Precise machining
Mold element design
Mold develop project 2
Mold manufacturing
Mold design, Product design
4th - Mold develop project 3
Assembly and repairing
High speed machining
Process analysis
Korean Die & Mold Industry Cooperative
21
1) The “Korean Die & Mold Industry Cooperative” was launched in 1980 and has 553 member
companies in 2014.
2) “InterMold Korea” began in 1980 and 22th InterMold Korea was held on March 10 2015.
koreamold.com intermoldkorea.com
Mold Valley
22
1) Bucheon city developed a mold industrial complex named “Mold Valley” in 2009.
2) 65 die & mold companies are co-working at the mold valley.
3) Korea Mold Center is built at the center of the Valley.
Mold Valley
Bucheon city
Mold Valley
Korea Mold Center
Mold Valley Area : 290,000 m2
Mold: 65 companies Other: 9 companies Employ: 1,700 persons Korea Mold Center
Korea Mold Makers
23
1) Mexican government officers visited Illwoo precision, NCBrain and Keonwoo precision.
2) Die and molds are used for mass productions of automotive structure and instruments
Sheet metal Plastic
Gun drill
24
Specialization
Mold design
NC Machining NC machining
Mold design
EDM EDM
Polishing assembly
Test injection
Polishing
Mold maker Outsourcing Standard
Standard elements
Standard mold base
26
Policy to foster Die and Mold SMEs
1) Competition and specialization of local Mold SMEs
2) Mexican mold industry association
3) International mold exhibition in Mexico : MoldMex 2016
A. Short-term policy to mold SMEs
Mold SMEs Mold Association MoldMex 2016
Cooperation Specialization Competition
Advertise Buy together Share knowledge
Mold makers Element companies Plastic companies Machine suppliers
27
Policy to foster Die and Mold SMEs
1) SME use equipment of Technological University and CENALTEC
2) Chihuahua mold valley
3) Mold development R&D
B. Long-term policy to government
Share Mold Valley Mold R&D
Technological University CENALTEC
Near university Common equipment
Mold development R&D funding
28
Policy to foster Die and Mold SMEs
1) SME use equipment of Technological University and CENALTEC
2) Chihuahua mold valley
3) Mold development R&D
B. Long-term policy to government
Share CENALTEC Tech. Univ.
Mold Valley Mold SMEs
R&D Fund Develop Mold
29
Policy on training and education
A. Technical high school and training center
Technical high school
CENALTEC
Mold Technician
Mold Technology
General Technician
Tech. Training Retired mold
engineer
Local SMEs
Spanish
1) Technical high school train general technology
2) CENALTEC employ retired Spanish mold engineers and start mold training program
30
Policy on training and education
B. University level education
Technological Universities
Institute of Technology
Design&Analysis Engineer
Professor + Translator
Basic mechanics
Mold making Technologist
Mold education Korea
Polytechnics
Tech. training Local SMEs
Gyeongsang Nat. Univ.
Summer school
Process analysis
1) Technological Universities invite professors from KP to stat mold education program
2) Institute of technology send students to GNU to learn process analysis
31
Policy on Mexico Korea partnership
A. Match making of local SMEs and KODMIC
1) 3 companies (CADISA, CBQ Technologies, HASI) joined MOU with KODMIC at March 2015.
2) Chihuahua mold makers get order of OEM companies and makes mold with Korean
technology
CADISA
CBQ Tech.
HASI
International Enterprise
Korea die & mold industry cooperative
600 enterprises
Design & Fabrication Maintenance
Stamping Die
Injection Mold
Injection Mold
+
32
Policy on Mexico Korea partnership
B. SMEs + University + Korean mold maker
1) Chihuahua local SMEs starts maintenance service and mold making business with the
equipment of Technological University and technology of Korea mold makers
Supply
Korean mold makers
Local SMEs
Technological University
Technology Mold design
Customer data Maintenance
Experience Training
Facilities Worker
Inte
rnational ente
rprise
Export
Repair
Worker
33
Policy Recommendations
C. Korea Mold Technology Center in Mexico
1) Mexico rent building (80 x 20 x 8 m) for 15 years + Korea establish Mold Technology
Center with 20 equipment($4 million)
2) Mexico learn Korean mold technology. Korea exports and maintain mold to automotive
company in middle Mexico
Mexico
Building 1,600 m2
8 m
Korea
Technology & 20 equipment
34
Policy Recommendations
C. Korea Mold Technology Center in Mexico
1) Korea Mold Technology Center become a partner of Mexican mold companies and trains
automotive mold repairing technology in the space with the equipment of the center.
Korea Mold Technology Center
Local mold SMEs
35
Policy on Mexico Korea partnership
D. Sends workers to Korean mold makers
1) If the Mexico government sign a MOU with Korean ministry of employment and labor, mold
technology can be improved
2) Korea has an Employment Permit System (eps.go.kr) which are employing 40 thousand
people from 15 member countries
Minister of employment and labor
Mexico government
1. MOU
Mexican Worker
2. Apply
Korean Mold SME
2. Apply 3. Permission
4. CCVI Korean
Embassy 5. Visa 6. Enter
TOPIC
7. Mold technology