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Practical tips Increase your RTQFWEVKQPGHƂEKGPE[
Knowing what counts! #EQORCP[oUUWEEGUUKUPQEQKPEKFGPEG2TQFWEVKQPGHƂEKGPE[EQWPVU And it counts throughout the entire value-added chain – from product design right through to production planning, and including preFQOKPCVKPIKPƃWGPEKPIHCEVQTUUWEJCUGPGTI[OCPCIGOGPVQTVJG appropriate corporate strategy. How are things at your company? Do you make rational use of your resources and exploit all available potential? With inspiring tips and concrete examples, ARBURG wants to motivate you to track down improvement potential in your injection moulding facility and to actively exploit this. 6CMGVJGƂTUVUVGRsKVYKNNDGYQTVJKV
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Our practical tips consist of ten modules that can also be applied individually and a self-test: Product design ........................4 Mould technology ..................6 Machine technology...............8 Peripherals ............................10 %QPƂIWTCVKQP .......................12 Process integration ...............14 Process control ......................16 Production planning .............18 Energy management ............20 Corporate strategy ...............22 2WV[QWTRTQFWEVKQPGHƂEKGPE[ to the test! ............................24 3
Product design
Production GHƂEKGPE[
Practical tips Do you use computer-aided simulations to design components and FGƂPGVQNGTCPEGUCRRTQRTKCVGN[HQTRNCUVKEU! When designing products, do you pay attention to angles and radii, to enable a smooth injection moulding process? Do you reduce wall thicknesses to save on materials and shorten cycle times? Do you combine plastics, e.g. in order to integrate functions in the component or minimise production steps? Do you select materials carefully with a view to reducing the energy requirement of the production process from the outset? Do you look into the possibility of using recycled or recyclable materials, in order to reduce waste? Do you think about using new materials, e.g. to improve material input or suitability for processing?
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Practical example By replacing PA 6 GF 30 with Ultramid® High Speed – a plastic with KORTQXGFƃQYEJCTCEVGTKUVKEUsVJGRTQEGUUKPIVGORGTCVWTGECPDG reduced by approx. 40°C, with comparable mechanical properties. So, for the production of a spinning Energy requiretop weighing 17.3 g, the energy requirement of the ment - 0.2 kWh cylinder module was reduced by around 15% and Cycle time the cycle time by about 10%. - 0.97 s
Further information
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Mould technology
Production GHƂEKGPE[
Practical tips Do you use computer-aided simulations to shorten development times and optimise the injection moulding process? Do you endeavour to achieve a stable production process? Examples: Do you reduce moving mould elements? Do you ensure good demoulding? Do you use hot or cold runners to save on materials? Do you insulate heated moulds to reduce the energy required for temperature control? Do you segment mould temperature control to ensure good process control? Do you use near-contour cavity cooling to enable fast cycles? With multi-component applications, do you examine the use of robotic technology as an alternative to transferring parts in the mould? The advantages are simple, cost-effective mould technology. Do you ensure that media channels are generously dimensioned so that optimum cooling and temperature control can be achieved? &Q[QWFGUKIPOQWNFUVQRGTOKVVJGJKIJGUVRQUUKDNGKPƃQY temperatures to be selected? Do you pay attention to the quality of the cooling water, to ensure pipe cross-sections remain unobstructed?
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Practical example To counter energy losses, insulation of hot moulds with respect to the environment and the mounting platens is important. In this way, during the production of optical lenses of PC with a mould temperature of 90°C, it was possiEnergy ble to more than halve the energy requirement for requirement temperature control. - 1.1 kWh
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Machine technology
Production GHƂEKGPE[
Practical tips When selecting machines, do you focus on functionality and performance and not just on energy requirement? Are you aware of the potential savings that can be achieved through high-quality technology? Examples: Fast cycles through simultaneous movements. Good process stability through high reproducibility. High availability through reliability. Do you compare achievable unit costs, not just the pure investment costs of the various injection moulding solutions? ARBURG uses a cost-effectiveness calculator to determine the most GHƂEKGPVUQNWVKQPHQTVJGCRRNKECVKQPCVJCPFHTQOVJGXCTKGV[QH products on offer. Do you reduce the production energy requirements through the targeted use of IE2 motors, speedcontrolled pump drives or electric drives? Do you examine the possibility of improved insulation of cylinder OQFWNGUHQTURGEKƂECRRNKECVKQPUVQTGFWEGGPGTI[TGSWKTGOGPVU! Do you consider liquid cooling of drives to reduce waste heat? This is particularly important in air-conditioned areas of production.
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Practical example Electric machines may be more expensive, but they deliver a higher performance than standard hydraulic machines. In a comparison of both types of machine for the production of drippers for irrigation systems, the Energy requireresult is as follows: With an electric ALLROUNDER, ment - 1.06 kWh/kg the energy requirement can be reduced by around Cycle time 45% and the cycle time by 20%. So, the extra - 0.83 s investment pays for itself within a few months.
Further information
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Peripherals
Production GHƂEKGPE[
Practical tips Do you control and monitor peripherals centrally to ensure high process reliability? Do you ensure simple and, ideally, uniform control to reduce time spent on programming and training? Do you employ speed-controlled, electric drives instead of pneumatic systems for automation? The advantages are simple set-up, low energy requirement, precise sequences and short cycle times. Do you check your compressed air system regularly for leaks, in order to detect and rectify any leakage at an early stage? &Q[QWCFCRVKPƃQYVGORGTCVWTGUQHEQQNKPIWPKVUVQGCEJ injection moulding process, to reduce cooling costs? Do you keep media supply lines short and insulate hot areas to reduce the energy requirement for cooling and temperature control units? Do you ensure that media lines are generously dimensioned so that optimum cooling and temperature control can be achieved? Do you pay attention to the quality of the cooling water, to ensure pipe cross-sections remain unobstructed? Do you clean cooling water pipes regularly to prevent the formation of deposits and therefore extended cooling times?
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Practical example Unlike pneumatic devices, sprue pickers with servo-electric movement axes do not require any set-up when changing orders. In addition, the servo motors enable simultaneous, stroke-dependent and exceptionally dynamic and fast movements. In this way, the cycle for producing Cycle time a token holder became around 10% faster. - 1.4 s
Further information
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Production GHƂEKGPE[
Practical tips Do you tailor the performance of machines and peripherals precisely to suit the product range to achieve a perfect combination in terms of energy and the technical process? Do you select and dimension individual components in line with the relevant requirements, in order to reduce cycle times and energy requirements? Do you endeavour to ensure high utilisation of the injection unit? #UWVKNKUCVKQPKPETGCUGUVJGURGEKƂEGPGTI[TGSWKTGOGPVHCNNU Therefore, fast cycles are also desirable from an energy point of view. Do you exploit the diverse range of modular equipment and expansion stages to the full, and so adapt technology to suit your needs? As your technology partner, ARBURG can provide you with detailed advice on the right technical equipment. Using an intelligent, “learnKPIqCRRNKECVKQPFCVCDCUGYGCTGKPCRQUKVKQPVQIKXGYGNNSWCNKƂGF advice and provide a detailed concept for processing technology. Do you make use of the ARBURG Customer Center for detailed machine comparisons and mould and process tests?
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Practical example A machine concept for especially high productivity is achieved by combining servo-electric drives for mould movement and dosage with hydraulic accumulator technology for injection. For the production of an IML container, with Energy requirethis solution it was possible to reduce the cycle time ment - 0.15 kWh/kg D[CPFVJGURGEKƂEGPGTI[TGSWKTGOGPVD[ Cycle time 15%, compared with a standard hydraulic machine. - 1.8 s
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Process integration
Production GHƂEKGPE[
Practical tips Do you integrate upstream and downstream tasks in the injection OQWNFKPIRTQEGUUVQQRVKOKUGNQIKUVKEUCPFVJGOCVGTKCNƃQY! Do you link individual work steps together in a targeted way to shorten throughput times or reduce transport distances? As a main contractor, ARBURG provides you with all-round advice: from project planning of production cells through to all the necessary services. Do you automate the feed of inserts, to increase process reliability and stability? &Q[QWWUGTQDQVKEU[UVGOUHQTIGPVNGTGOQXCNQHƂPKUJGFRCTVUVQ keep rejects to a minimum? Do you perform quality assurance inline, in order to react immediately to problems and reliably separate substandard parts? Do you coordinate machines, moulds and automation systems with one another at an early stage to achieve the best possible results in terms of investment costs, cycle times and process stability? In the early design phase, do you examine whether you have CNNQYGFUWHƂEKGPVƃGZKDKNKV[HQTHWVWTGCRRNKECVKQPU! Do you control the machine and robotic system centrally, so that UGSWGPEGUCTGOWVWCNN[JCTOQPKUGFHQTVJGURGEKƂECRRNKECVKQPVQ the best possible extent?
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Practical example The production of a toy buggy requires several work steps: inserting the metal axles, removing the individual parts KPENWFKPIURTWGCPFƂVVKPICZNGUEJCUUKUCPFTQQHVQ ETGCVGVJGƂPKUJGFRTQFWEV9KVJCTQDQVKEU[UVGO Availability all these steps can be automated. The result is an + 10% autonomous, constant production process. Cycle time And the simultaneous removal and insertion of -5s parts means the cycle is also around 15% faster.
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Process control
Production GHƂEKGPE[
Practical tips Do you use machine control systems centrally to ensure consistent monitoring of quality and to keep rejects to a minimum? Are you familiar with the available options for quality and process control? Example: Do you analyse the signals from the supply of granulate, compressed air or water and from automation components? Do you make use of automatic On/Off functions for unmanned preparation? Do you use start-up programs for a fast, controlled and automated production start? Do you focus on achieving a smooth, uninterrupted production process when setting up? Do you also search for ways to reduce cycle times, so that the machine is optimally utilised? Do you set process parameters individually to save energy? Examples: Do you reduce clamping and nozzle contact forces during the residual cooling time? Do you make use of the entire cooling time for dosage? Do you only open moulds as far as necessary? Do your employees regularly receive thorough further training by specialists, so that they can fully exploit the potential of the machines? Do you take advantage of customised, on-site training courses, so that ongoing production processes can be directly optimised?
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Practical example When robotic systems are fully integrated in the machine control system, sequences can be optimised in a targeted way; for example if the the robotic system already moves into the mould during the opening movement or its movement is synchronised with the ejector. In Cycle time this way, the cycle time for producing a stacking box -2s can be reduced by around 10% – with no additional investment costs.
Further information
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Production planning
Production GHƂEKGPE[
Practical tips Do you regularly switch pumps off during machine downtimes to save energy? Do you compare “pump operating hours” with “operating hours in automatic mode”? Do you ensure preventive maintenance to prevent unplanned downtimes? Do you use computer-aided planning for your production, to avoid time-consuming manual data acquisition and simultaneously improve machine utilisation through greater transparency? Do you keep track of essential maintenance work in order to have a precise overview of available capacity? Do you optimise batch processing times to keep set-up processes to a minimum? Do you organise set-up processes and prepare them carefully to minimise machine downtimes? Example: Do you maintain a wellorganised tool cart? Do you practice set-up processes so that they can be optimised and systematised? Do you continually record production data to enable detailed analysis and seamless documentation? Do you archive setting data centrally so that you can always access the most recent, optimised data?
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Practical example A host computer system eliminates the need for manual data acquisition. Production planners save around 15 minutes per order; while operators save approx. 5 minutes per shift and machine. As programs are transferred online, set-up processes are comWorking time pleted about 6 minutes faster. Downtimes are immedi- 1500 h or more ately obvious from a central point and can therefore be Downtime TGEVKƂGFOKPWVGUHCUVGTQPCXGTCIG5QQXGTC[GCT - 500 h or more huge time savings are achieved in total.
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Energy management
Production GHƂEKGPE[
Practical tips Do you analyse the energy requirement of processes, machines and peripherals, so that you have a solid basis for decision-making and can achieve further optimisation? Example: Peripherals can sometimes dramatically increase the overall energy requirement. This is particularly the case with technical parts. Do you make use of the energy measurement system integrated in machines to automatically record and document energy values? &Q[QWWUGVJGURGEKƂEGPGTI[TGSWKTGOGPVCUCMG[KPFKECVQTHQT performing meaningful comparisons? Do you have statistics on the energy requirement? Systematically recording these helps to identify potential energy savings. Do you monitor your energy requirement, so that you can introduce organisational measures to pre-empt expensive current peaks? &Q[QWURGEKƂECNN[NQQMHQTRQVGPVKCNGPGTI[UCXKPIU!'ZCORNGU Do you check your compressed air system regularly for leakage? Do you separate machine and mould cooling circuits? Do you use energy several times over through heat recovery?
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Practical example Preparing compressed air is an extremely energy-intensive process: only approx. 4% of the electrical energy used is available as pressure energy. Compressed air systems must therefore be inspected regularly. At a pressure of 7 bar, several Energy OKPQTNGCMUŨVQIGVJGTGSWKXCNGPVVQCJQNGLWUVOO requirement KPFKCOGVGTŨCNNQYCUOWEJCUNQHEQORTGUUGF - 8.8 kWh air per second to escape unused into the environment.
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Corporate strategy
Production GHƂEKGPE[
Practical tips +URTQFWEVKQPGHƂEKGPE[CPKPVGITCNRCTVQH[QWTUVTCVGI[! Do you strive to achieve the rational use of all resources continuously and therefore for the long term? Do you set realistic goals, e.g. for higher productivity, fewer rejects or lower energy requirements? Do you keep your employees informed about set goals and planned measures? Are your employees aware of the costs resulting from increased energy requirements, use of materials and personnel, set-up times, downtimes and rejects? Do your employees know their responsibilities with regard to RTQFWEVKQPGHƂEKGPE[CPFVJGEQORCP[oUUGVQDLGEVKXGU! &Q[QWTCKUG[QWTGORNQ[GGUoCYCTGPGUUQHRTQFWEVKQPGHƂEKGPE[ VJTQWIJQPIQKPIVTCKPKPIEQWTUGUCPFSWCNKƂECVKQPU! Do you systematically identify potential and exploit it to the full? Example: Do you analyse recurring sequences and problems?
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Practical example At ARBURG, video analysis has proven to be a valuable tool for optimising set-up processes. During tool changes on a turning and milling machine, video analysis showed that the employee had to turn around 36 times in total. Thanks to a few low-cost measures, sequences Set-up time were improved and set-up times halved. - 30 min.
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2WV[QWTRTQFWEVKQPGHƂEKGPE[VQVJGVGUV 1WTUGNHVGUVJGNRU[QWKFGPVKH[LWUVJQYGHƂEKGPVRTQFWEVKQPKUCV your injection moulding facility and where there is potential for improvement. 1. What role does product design play for you? a) Product design appropriate for plastics and targeted material selection are a matter of course. Customers’ attention is drawn to potential improvements from time to time. b) As well as product design appropriate for plastics CPFVCTIGVGFOCVGTKCNUGNGEVKQPGHƂEKGPE[ETKVGTKCUWEJ as energy requirements and cycle times are taken into account. Customers’ attention is drawn to optimisation opportunities in a targeted manner c) Only functionality is taken into account during product design, regardless of the manufacturing process. Customers do not receive any feedback on product design 2. What is important to you in terms of mould technology? a) Mould costs are the top priority b) Ensuring a stable production process is more important than mould costs E #UYGNNCUCUVCDNGRTQFWEVKQPRTQEGUUGHƂEKGPE[ criteria such as material requirements and cycle times are taken into account 3. How do you select your machine and drive technology? a) I explicitly enquire about alternative machine and drive technology b) I seek out alternatives and compare them in economic terms as a matter of course c) Same machine and drive technology as always, without looking into alternatives No multiple answers possible 24
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4. How do you equip your production in terms of peripherals – e.g. robotic technology? a) The machine and robotic system have separate control systems b) The machine and robotic system form a single production unit with central machine control system c) The machine and robotic system have separate control systems or form production units with a central control system a) b) c)
&Q[QWEQPƂIWTG[QWTRTQFWEVKQPHCEKNKV[ HQTGCEJURGEKƂECRRNKECVKQP! Regularly Occasionally Never
0 10 5
10 5 0
6. Do you look for solutions to automate or link processes? a) Never b) Occasionally c) Regularly
0 5 10 Subtotal 25
7. Do you systematically optimise your production sequences? a) Regularly b) Occasionally c) Never
10 5 0
8. Do you plan your production sequences, such as set-up, for example? a) Never b) Occasionally c) Always
0 5 10
9. How much do you know about the energy requirement of your production? a) I know the energy requirements of important processes precisely b) Manufacturer information is available regarding the energy requirements of machines and peripherals c) No detailed measurements or estimates are available regarding the energy requirements of processes, machines or peripherals 10. Do you seek to identify measures for minimising energy requirements, material input, personnel, production steps, processing, set-up times, downtimes and rejects? a) Never b) Occasionally c) Regularly
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10 5 0
0 5 10
Evaluation of results 0-40 points +VoUVKOGVQIGVIQKPI6JGTGKUUKIPKƂECPVRQVGPVKCNHQTGPJCPEKPI RTQFWEVKQPGHƂEKGPE[VJTQWIJQWVCNOQUVVJGGPVKTGXCNWGCFFGF chain at your company. Your ARBURG contact will be pleased to advise you on how you can reduce your unit costs.
45-80 points 6CMGCENQUGTNQQM;QWCTGCNTGCF[YQTMKPIXGT[GHƂEKGPVN[ in some areas. Close examination, however, is sure to reveal further potential for unit cost reductions. Make use of the support offered by experienced ARBURG specialists to maximise your competitive edge.
85-100 points %QPITCVWNCVKQPU;QWCTGQRGTCVKPICVCJKIJNGXGNQHRTQFWEVKXKV[ CPFCTGCNTGCF[GZRNQKVKPIUKIPKƂECPVRQVGPVKCNUHQTTGFWEKPIWPKV costs. Continue to look out for innovations and promote new ideas. Make use of ARBURG’s unique pool of expertise and gain a leadership position in production over the long term. ARBURG could well imagine publishing a success story report on your company in its “today” customer magazine.
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680810_EN_GB_022013 · Subject to alterations Printed in Germany
ARBURG GmbH + Co KG Postfach 11 09 72286 Lossburg Tel.: +49 (0) 74 46 33-0 Fax: +49 (0) 74 46 33 33 65 e-mail:
[email protected]
