Bazele Injectiei Mase Plastice

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    [Injection Section]

    Model Change Standard

    Manual

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    Electronic industry during the Digital Age has shortened the Life Cycle of the product dramatically,

    and in a situation where prices change quickly, continuously introducing new products and reflecting

    the needs of various customer has been prioritized as the main factor for the companys survival.

    Especially, the increase of material cost due to recent Won currency boost and high petrol cost, the

    cost price pressure is growing, Japanese companies efforts, thanks to the structure adjustment and

    internal economic recovery, are concentrating on strengthening their expansion on their lead in the

    market.

    Our company must playing the leading role, by establishing a rational Process in order to expand

    the cost and speed competitiveness.

    Especially, as for our company and vendors in which the foundation is based on increase in

    production amount, production system operation of various products variable, On time 3 Days Fixed

    Production Plan, Fixed amount production, we must ensure that the company and vendors Model

    Change time be shortened in order to achieve a World Class Corporate.

    In such aspects, we would like to provide the drive methods to improve the people involved by

    themselves at the manufacturing site, by making use of the Press Equipment Model Change Standard

    Manual. The purpose for developing this Press Equipment Model Change Standard Manual is :

    First, Speed insurance through Model Change Time Single Systemization.

    Second, Improve Operation Rate and Capa. through Model Change time shorten.

    Third, Establish an Effective Factory through Standardizing Model Change Work Process

    and Improvements.

    The core capability in the Electronic industry is speed.

    I believe that this Press Equipment Model Change Standard Manual is a compulsory guide to

    achieve the World Class Corporate.

    Through continuous improvements and preservation, we request for your active usage to create a

    competitive factory.

    September 2006

    Corporate Business Innovation Team

    Vice President Yoon Ju Hwa

    Introduction

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    . Check List

    . Overview

    . Model Change Work Order

    Attachment Documents

    Attachment 1.

    Improvement steps for Model Change Single

    Systemization

    Attachment 2.

    Model Change Work Improvement Point

    Attachment 3.

    Improvement Cases

    Content

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    Check List

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    1. Outer Preparation Check

    2 Inner Check List

    Ejection Model Change Standard Manual

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    Ejection Model Change Standard Manual

    2. Inner Preparation Check List

    3. Outer Preparation Check List

    Ejection Model Change Standard Manual

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    Ejection Model Change Standard Manual

    1. Outer Preparation Check List

    Standard Work Order Management PointStd

    Time(s)Ref.

    01 Obtain Production Plan from the Supervisor 30mins before work -Page 9

    02 Create Model Change Chart 20 mins before work 30003 Go to Mould Storage Area with the Hoist 90 mins before Model Change 30

    Page 1004Find the Mould for Model Change and Connect tothe Hoist

    Appoint Mould StorageAddress

    30

    05Move the mould for Model Change to Pre-HeatingWaiting Area

    Locate Pre-Heater nearInjection Machine

    120

    09Find the Appropriate Tool Cart from the ToolStorage

    10 mins before Model Change 30Page 14

    10 Move the Tools Cart to the Facility Area Store Tools in Tool Storage 60

    2. Inner Preparation Check List

    Standard Work Order Management PointStd

    Time(s)Ref.

    01 Swith Injection Machine to Manual and stop Mesasure Model Change Time -

    Page 1902 Switch OFF the Heater Controller Power 203

    Use Injection Machine Nozzle Lever to RetreatNozzle

    Standardize Nozzle RetreatDistance

    2

    04 Open Injection Machine Front Safety Door 5Page 20

    05 Apply Grease on the Mould Surface Maintain Rust, Core Parts 15

    09After applying Grease, Check for Errors onInner Mould

    5

    Page 2310 Close the Mould Manually Check PIC B Completion 5

    11 Lower Hoist onto Mould 20

    16 Connect Hoist and Mould Make the rope tight 5 Page 25

    17 Release Auto Clamp Pressure 10

    Page 2618 Separate the Gasket 10

    19 Separate 2 fixed side, 2 moving side clamps 10

    21 Open Injection Machine's Moving Plate Manually 10Page 2822

    Separate Production Complete Mould fromInjection Machine

    Beware of Locate Ring Damange 5

    23 M ove Production Complete Mould to Assigned Area Add Legs to Mould 50

    27 Separate Hoist from Production Complete Mould 15

    Page 3028 Connect Hoist to Model Change Model Check Eye-Bolt Connection 15

    29 Move Model Change Mould to Injection Machine 20

    30 Lower Model Change Mould to Injection Machine 30

    Page 3131 Stick Locate Ring to Injection Machine 30

    32 Center Mould Locate Ring and Injection Nozzle Indicate Center 15

    35 Close Auto Clamp to Mould Check Mould Plate Thickness 10Page 33

    36 Switch ON and Fix Auto Clamp Control Box 10

    39 Lower Hoist and Loosen the Line 10

    Page 3542 Move Hoist to Production Complete MouldLocation 20

    47 Open Injection Machine Front Safety Door 5Page 38

    48 Clean Grease on Inner Mould Prepare Hand Rug 30

    52 Forward Injection Machine Cylinder 12

    Page 4053 Squeeze out Over-Heated Resin inside NozzleCheck Resin Residue inside

    Mould30

    54 Switch Injection Machine to Semi-Auto 5

    55 Adjust Detail Injection Conditions 5

    Page 4156 Inspect until Production Inspection Standard 120

    57 Record Model Change Time -

    Standard Work Order Management PointStd

    Time(s)

    Ref.

    22 Indicate Completion on Model Change Chart 20Page 42

    23 Move model change cart to waiting area 60

    3. Outer Preparation Check List

    1

    PIC A Check List

    Ejection Model Change Standard Manual

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    Ejection Model Change Standard Manual

    Standard Work Process Management PointStd.

    Time (s)Ref.

    06 Connect the Mould for Model Change to Pre-Heater Before (Pre-Heating Time + 10mins) 60

    Page 1207Check Pre-Heater's Temperature Setting andCheck For Leaks

    Mould Temperature +% 30

    08After Connecting the Valve Gate Heater, Set theTemperature

    Melting Temperature 90% 40

    11 Move the Hoist to the Pre-Heating Mould 10 mins before Model Change 60

    Page 1512 Separate the Pre-Heater from the Mould Check Mould Temperature 10

    13 Off the Heater Power and Disconnect the Wires 10

    14 Connect the Pre-Heated Mould to the Hoist Check Eye-Bolt Connection 10Page 16

    15Move the Pre-Heated Mould to the Model ChangeInjection Machine

    Appoint Mould Waiting Area 300

    16 Separate the Pre-Heated Mould from the Hoist 10Page 17

    17 Move the Hoist to the Upper Injection Machine Indicate Center Indication 30

    18 Close Production Mould Coolant In/Out Valve 3 mins before Model Change 5

    Page 1819 Open the Air Out Valve Standard Valve color 5

    20 Supply Air and Remove Coolant Residue Check Coolant Removal 60

    Standard Work Process Management PointStd.

    Time (s)Ref.

    06 Open Injection Machine Back Safety Door 5

    Page 2107 Separate Coolant Hose on Fixed Side 10

    08 Separate Coolant Hose on Moving Side 10

    12 Separate Heater Connector Standardize Connector Pin 10

    Page 2413 Separate Air hose 10

    14 Separate Timer Wire 1015 Connect Production Complete Mould to Hoist Check Eye-Bolt Connection 15 Page 25

    20 Separate Clamp upon PIC A's Signal 10 Page 27

    24Check the Model of the Model Change mould fromInjection Machine

    Check Injection ConditionInput

    30

    Page 2925 After Model Check, Retrieve Injection Condition 5

    26 Check Injection Condition of Model Change Mould 25

    33 Input Gas Conditions of Model Change Mould 30Page 32

    34 Check and Adjust Heater Supplier 30

    35 Close Auto Clamp to Mould Check Mould Plate Thickness 10Page 33

    36 Switch ON and Fix Auto Clamp Control Box 10

    37 Connect Fixed Side Coolant Host Check Cooling Block 15Page 34

    38 Connect Moving Side Coolant Hose Check In/Out Connection 1540 Separate Hoist from Mould 15 Page 35

    42 Adjust Mould Thickness in Injection Control Panel 20Page 36

    43 Open Mould 5

    44 Climb Up Injection Machine and Connect Wires 10

    Page 3745 Connect Air Hose Check Air Supply 10

    46 Connect Timer Wire 10

    49 Set Injection Machine Cooling ConditionsStandardize Surrounding

    Components per Equipment10

    Page 3950 Set Heating Conditions 10

    51 Set Gas Supplier Conditions 10

    Standard Work Process Management Point Std. Time(s) Ref.

    21 Move Proudction C

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