Are you fixing it right the second or third time? Lessons in mold repair, preventative maintenance and people.

Scott PhippsOwnerUnited Tool & Mold Duncan location: (864) 859-8300scott@utminc.com

The year was 1978. Scott Phipps started in the mold making trade sweeping floors. Scott posses the ability to see problems as opportunities. Driven with a strong work ethic that is fueled by passion Scott has advanced to now owning his own group of companies: United Tool and Mold. UTM was established in 1995 and currently operates from three locations. Two are located in South Carolina and one in Alabama. UTM is unique in the mold repair industry because of its global presence and overall approach to problem solving. Successfully supporting the largest Tier I and II plastic injection molders by working side by side with the largest shops in the USA, Canada ,Germany , Portugal, China, Japan and Korea. UTM has emerged as the go-to resource in mold repair.

Scott feels he really started adding value to his customers when he combined the knowledge of mold making, mold repair and process engineering. Having this understanding helped him accurately determine root cause for most plastic injection molding problems.

Scott Phipps, owner of UTM

Does this scenario sound familiar?

Your phone rings : It’s the molders Program Manager, Process or Tooling Engineer. The mold is not working and needs picked up right now. Of course they owe parts yesterday……

It could be one of many problems like flash, manifold is “no good”, splay, gate blush part is warping or cycle time cannot be achieved.

Nest step:

•Mold is shipped to your facility.

•Last shots included? If so marked up? Documented action plan?

•Cost to expedite is not their problem since the molder has classified this as ‘warranty’ repair.

Q: How can you diagnosis the real issues with out a complete overview?

A: You cant. Nobody can.

It starts with communication:

•Technical problems can’t be solved accurately and completely with poor communication.

•Have you considered the entire process when trouble shooting?

•Do you understand the principals of the entire process?

•Having the most basic understanding about the physics of molding is key in solving the issues that come up.

Building molds to budget: Considering the right factors during the mold build budget planning session will lead to success in production.

When cost outweighs performance and quality the resulting mold will not have or be:

•The best mold for the application.

•A PM plan based on cycle counting.

•A clear understanding of the real cost accrued from not executing a PM plan for the mold.

•The largest process window for production. * This is key to overcoming environment and equipment variables during production.

•You will never know when your next major issue will overwhelm you. Its like playing Russian roulette with injection molding.

Know what your jumping into: Building molds with maintenance in mind from the beginning:

•Preventative maintenance planning and execution is the key to keeping a mold capable and consistent for producing parts to plan.

•Design the plan to minimize labor and fixed cost while maximizing the return on investment.

•Capacity planning (labor hours and machinery) is critical if the molder is serious about a PM plan. Do they have enough labor and the right equipment to execute a real PM plan?

•The mold maker or mold repair company should be involved upfront when the PM plan and ultimately the budget is set.

•All to often involving them is an after thought that results in cost limitations for the PM plan. Ultimately compromising the completeness of the PM plan.

Process monitoring: Once the mold is built and the PPAP process is established you have a baseline, It’s the target for repairs. The images on the right are:

•The result of an operator increasing the shot volume because short shots were occurring, They then walked away for 30 minutes.

•Initially blame was put on the mold maker for installing the manifold system incorrectly. This was incorrect.

•The teams came together to solve the problem and all agreed on the root cause diagnosis.

•The root cause: Press barrel was out of alignment to the mold by 5mm or more. Preventing the correct seal off that resulted in a leak.

•The end goal: Produce quality parts consistently over time within the budgeted plan.

The devil is in the details:

Paying attention to details will go a long way when trying to determine root cause of a molding issue.

•Don’t assume anything.

•Verify the information you are being given before using it to trouble shoot.

•Employ the “Stop and Fix” mentality: •This is a balance of production demand and time available for the repair. •A interim repair. •A complete repair plan and then the executing that plan. •One of the hardest things to do is go back and fix while in the day to day battle.

Direct gated part: •B side is missing dimple. •Result: Thin wall to thick wall flow.

The path to root cause analysis:What are your tools?

1. The PPAP approved process setup sheet.

2. The process control system of the press.

3. The material data sheet.

4. Marked up parts from last run.• Retain a full shot.

5. The Hot Runner Manifold controller (diagnostic capable is important).

6. Resin or other supplier expertise.

7. Mold repair/Mold Making/Mold design expertise.

8. Thermal imaging.

9. Experience, collaboration, teamwork.

Where will they come from?How will you fill and retain the increasing demand for employee’s with diverse skills?

1. The need for skilled labor’s demand is increasing.

2. Finding someone with experience that has worked in multiple disciplines is becoming tougher and tougher.

3. Training: Internal and external. 1. Training on your own is increasing

in popularity. 2. Companies like Toolingdocs.com

and Tool Stats can train your team for you: onsite or at their facility.

4. Teach common sense…..

United Tool & Mold scott@utminc.com

(864) 859-8300

ROI Rich Oles Industries, LLCricholes@gmail.com

(616) 610-7050

Check out the “Pellet 2 Part” series in Mold Making Technology magazine.

Thank you!Leaders are visionaries with a poorly developed sense of fear, and no concept of the odds against them. They make the impossible happen." - Robert Koffler Jarvik