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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
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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
