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How can one Generate Maximum Profit from a Moulding Shop
Ferromatik Milacron India Pvt. Ltd.
Hyderabad
Company Confidential – All rights reserved1 June 4, 2014
M. Amarnath
Sr. Manager - Sales
The Efficiency Conundrum
Output – To Maximize�Higher Production
�Higher Utilization of Equipments
Efficiency (ηηηη)))) = Output
Input
Company Confidential – All rights reserved2 June 4, 2014
Input Endowment – To Minimize�Raw Material
�Energy Consumption
�Manpower
�Space
Benefits of Efficiency
�Cost Competitive
�Consistent Quality Performer
�Maximum utilization of Resources
�Increase Up Time of Equipments
�Consistent Supplier of Choice$WIN MORE BUSINESS
Company Confidential – All rights reserved3 June 4, 2014
�Consistent Supplier of Choice$WIN MORE BUSINESS
Efficiency - Quality components and Cost effective
production in stipulated Time while maximizing the use of
Resources applied
Elements of Efficiency
�Factory & Shop Floor Layout
�Waste Elimination at Various Stages
�Automation for Consistency
Company Confidential – All rights reserved4 June 4, 2014
�Selection of Appropriate Process Technology
�Selection of Appropriate Equipments
Elements of Efficiency
�Factory & Shop Floor Layout
�Waste Elimination at Various Stages
�Automation for Consistency
Company Confidential – All rights reserved5 June 4, 2014
�Selection of Appropriate Process Technology
�Selection of Appropriate Equipments
Layout Characteristics
�Effective use of available Space – Becoming Scarce Resource
�No Hindrance & Smooth Flow of Material:
Raw Material Production Parts Assembly
Packing Finish Goods Shipment
�Better Supervision - A good plant layout enables the supervisor
to have a hawks eye on the entire shop floor
Company Confidential – All rights reserved6 June 4, 2014
�Layout should address High Safety & Working Conditions –
High Employee Morale
�Improved utilization of Manpower - Process flow should be
planned in such a way that least Movements of Manpower is
carried out
Elements of Efficiency
�Factory & Shop Floor Layout
�Waste Elimination at Various Stages
�Automation for Consistency
Company Confidential – All rights reserved7 June 4, 2014
�Selection of Appropriate Process Technology
�Selection of Appropriate Equipments
Waste Elimination
What is “Waste” ?
Whatever does not add value or Deliver Benefit
“Waste” We can see in
�Floor Space
�Walking Distance
Company Confidential – All rights reserved8 June 4, 2014
�Inventory
�Rejection
�Cycle time
�Manpower
Waste Elimination
�Minimize the Time for Mould Change – Planned Preparation for Mould Change
�Runner less / Hot Runner Moulding
�Reduce Mould set up Time – Use historical Data for Quick Set up
�Automation – Material Loading System, Conveyor & Robots for increase
Company Confidential – All rights reserved9 June 4, 2014
consistency, Reduced Rejection & Effective utilization of Man Power
�Moulding Process Optimization
�Preventive Maintenance of IMM & Equipment
Elements of Efficiency
�Factory & Shop Floor Layout
�Waste Elimination at Various Stages
�Automation for Consistency
Company Confidential – All rights reserved10 June 4, 2014
�Selection of Appropriate Process Technology
�Selection of Appropriate Equipments
Automation
Areas of Possible Automation
�Mould Changing System
�Material Feeding System
�Product Removal & Transfer System
�Information Management System
Company Confidential – All rights reserved11 June 4, 2014
AutomationScope for Automation in Moulding Shop
Material
Storage
Mould Stocker
Mould Temp.
ControllerMould
Clamper
Transfer Transferring Device
Stocker
Product Container
Material Feeder System
Product
Transfer SystemMould Changing System
Company Confidential – All rights reserved12 June 4, 2014
Grinder
Information Management
Data Setting & Monitoring
Material
Dryer
Material
feeder
Storage Controller
Injection Moulding Machine
Runner Removal
Part Remover
Product Container
Information Management System
Pro
duct
Rem
oval S
yste
m
Automation
Areas of Possible Automation
�Mould Changing System
�Material Feeding System
�Product Removal & Transfer System
�Information Management System
Company Confidential – All rights reserved13 June 4, 2014
Automation
Mould Changing System
�Mould Loading / Unloading
�Mould Clamping / Unclamping
�Mould Connections
Company Confidential – All rights reserved14 June 4, 2014
Automation
Mould Changing System
�Mould Loading
�Stationary tables
�Rail Carts
�Movable Carts
Company Confidential – All rights reserved15 June 4, 2014
Automation
Mould Changing System
�Mould Loading
�Mould Clamping
�Mechanical QMC
�Hydraulic QMC
�Magnetic QMC
Company Confidential – All rights reserved16 June 4, 2014
QMC Video
Company Confidential – All rights reserved17 June 4, 2014
Automation
Mould Changing System
�Mould Loading
�Mould Clamping
�Mould Connections
�QRC for Water Connections
�QRC for Hydraulic Connections
�QRC for Multiple Connections
Company Confidential – All rights reserved18 June 4, 2014
Automation
Areas of Possible Automation
�Mould Changing System
�Material Feeding System
�Product Removal & Transfer System
�Information Management System
Company Confidential – All rights reserved19 June 4, 2014
Automation
Material Feeding System
�Auto Loaders
�Dozing Systems
�Ratio Loaders
�Central Conveying System
Company Confidential – All rights reserved20 June 4, 2014
Automation
Areas of Possible Automation
�Mould Changing System
�Material Feeding System
�Product Removal & Transfer System
�Information Management System
Company Confidential – All rights reserved21 June 4, 2014
Automation
Product Removing System
�Sprue Pickers
�Article Pick & Place Robots
�Finished Product Conveyer Belts
Company Confidential – All rights reserved22 June 4, 2014
Article Pick and place Robot Video
Company Confidential – All rights reserved23 June 4, 2014
Automation
Areas of Possible Automation
�Mould Changing System
�Material Feeding System
�Product Removal & Transfer System
�Information Management System
Company Confidential – All rights reserved24 June 4, 2014
PDA SOFTWARE INSTALLED
D
at
Automation
Information Management System
�Product Data Analysis Software
Company Confidential – All rights reserved25 June 4, 2014
Elements of Efficiency
�Factory & Shop Floor Layout
�Waste Elimination at Various Stages
�Automation for Consistency
Company Confidential – All rights reserved26 June 4, 2014
�Selection of Appropriate Process Technology
�Selection of Appropriate Equipments
Advanced Process
Multi-material Process Assisted moulding
Multi-Colour Multi-shot
Over-moulding Gas Water
Intermittent Insert
Selection of Appropriate Processing Technology
Company Confidential – All rights reserved27 June 4, 2014
Co-injection moulding
Intermittent
(marbling)
Insert
Lost-core
Sequential Simultaneous
Wooden
Pattern
Core backRotating tool Transfer
Elements of Efficiency
�Factory & Shop Floor Layout
�Waste Elimination at Various Stages
�Automation for Consistency
Company Confidential – All rights reserved28 June 4, 2014
�Selection of Appropriate Process Technology
�Selection of Appropriate Equipments
Selection of Appropriate Equipments
�Injection Moulding Machine
�Clamp unit
�Injection Unit
�Energy Platform
�Mould
�Number of Cavities
�Mould Material
�Peripheral Equipments / Auxiliaries
Company Confidential – All rights reserved29 June 4, 2014
�Peripheral Equipments / Auxiliaries
�Chiller
�Material Conveying System
�Material Drying System
�Scrap Grinder
�Utilities
�Cooling Tower
�Air Compressor
Measurement Matrices
� Uptime %
�Rejection %
�Revenue Per Sq. Meter
Company Confidential – All rights reserved30 June 4, 2014
�Profit Per Sq. Meter
�Revenue Per Person
�Profit Per Person
Create an Efficient Moulding Shop
Company Confidential – All rights reserved31 June 4, 2014