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Plastics Industry Workshop

Scott R. Kroeger

General ManagerHusky Injection Molding Systems, Inc.October 2004

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Typical Costs Drivers

17%

13%

50%

14%6%

60%

6%

22%

4%

8%

53%

19%

22%

2% 4%

44%

23%

13%

14%

6%

AutomotiveLarge tonnage

ClosuresCustom

PETPreforms

CustomMolder

Primary Equipment

Energy

Labor

Building & infrastructure

Maintenance

*Excluding resin

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Cost of an Injection Molded Part

Material

Machine

Molds

Labor

Cooling

Space

Other

Energy

Machinery

Heat, Vent, A.C.

Lighting

Chillers

Cooling Tower

Compressors

GrindersTools

Misc.

75%3%2%

1%

3%4%4%

8%

59%

11%

10%

9%4% 3%

2%

1% 1%

Source: Demag

ENERGYENERGY

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Analyzing PET Energy Consumption

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Machine - Increased Productivity

Part: 47g Preform

Cavities Tonnage Energy

(kWh/kg)

Cycle

Time

Energy

Cost for

76 MMunits*

Additional

Annual

ProductionUnits

Hydraulic

Hydromechanical60 275 0.24 14.5 $24,000 35 MM

All Electric 48 400 0.20 17.0 $20,000 -

* At $0.08/kWh

PET Application

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Typical Energy Requirements

Plasticizing 50%

Injection 17%

Clamp Stroke 13%

Core pulls/ejection 10%

Idle time 10%

Hydraulic Machine

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Electric Screw Drive

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1961 All Electric Machine

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Energy Consumption Comparison

Energy savings 16%

Parameter Unit of

Measure

Hydraulic

Screw Drive

Electric

Screw Drive

Shot weight g 41.6 41.6

Total cycle time s 5.88 5.81

Production power kW 26.87 22.7

90T, 32 cavity closure system

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Energy Consumption Comparison

Energy savings 11%

Parameter Unit of

Measure

5-7 Yr Old

H-M Machine

New

Generation

H-M Machine

Shot weight g 117.5 113.8

Total cycle time s 4.56 4.39

Production power kW 88.2 78.7

300T, 16 cavity cup system

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Energy Usage Comparison

0%

20%

40%

60%

80%

100%

Standard Hydraulic EnhancedHydraulic

Hybrid All Electric

Energy

Usage

All electric

claim 40-50%

improvement

over hydraulic

All electric

versus hybrid is

only 10-20%

40-50%10-20%

Source: Ferromatik Milacron article February 2002

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Mold Stroke Oil Usage

90 - 100 US tons:

Oil Consumption [ l ]Stroke 350mm (13.8") 0.638

Clamp up incl shutter 0.329

Decompression 0.104

Total 1.071

Hydraulic Clamp - 100 US tons :9 clamp cylinder diameter at stroke of 350 mm (13.8)

= 14.5 l + stroke cylinders

Lower speed

Larger hydraulic components, i.e pumps

Larger oil compression

Higher energy consumption

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Energy Machine Cooling

Hylectric machine makes use of water cooled motors,drives, gearboxes, hydraulic oil

In most cases, all-electric machines are completelyair cooled except for the feed throat

Requires an efficient HVAC system Consider typical plant cooling costs:

Tower water system: $150 per ton of cooling installed +0.2kw per ton to operate

HVAC system: $600 per ton of cooling installed + 1kw per

ton to operate

Tower water is a more efficient and cost effectivecooling method

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Enclosed Powerpack & Water-Cooled Motors

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Repeatability - Comparison

Hydro-mechanical 90 vs. 165 Ton All Electric

H-M All Electric

Parts Sampled 30 30

Average Shot Weight (g) 34.36 34.42

Shot Repeatability (6 sigma) 0.12 0.64

2 Cavity Cell Phone

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Additional Advantages of H-M

Machines

High injection rates

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Electric Injection Limitations

Instantaneous Injection Power

0

50

100

150

200

250

300

350

400

450

500

20 25 32 35 42 50 60 70 85 100 125 145 155 155 170 185 220

Screw Diameter (mm)

Power(kW)

Accumulator based Hydraulic Injection

Current "Practical" Servo Power Limit

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High Output Closure SystemsInjection Rates

2 X 64 cavity hot runner mold closure mold

2,500 cc/sec. required

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Additional Advantages

High injection rates

Lower clamp tonnage

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Test Results STM & MTM

Application Clamp Tonnage CycleCompetitive

MachineHydro-

MechanicalHybrid

CompetitiveMachine

Hydro-Mechanical

Hybrid

38 mm Closure 100 80 (20%) 6.0 5.2 (13%)

Thinwall Dish 55 20 (63%) 3.0 2.5 (17%)

Battery Cover 75 40 (46%) 10.0 8.6 (14%)

Cell Phone Housing 100 52 (48%) 18.5 15.2 (18%)

Cell Phone Housing 120 70 (42%) 14.0 12.6 (10%)

Oval Container 150 90 (40%) 6.0 5.0 (17%)

Oval Lid 90 50 (45%) 5.8 5.1 (12%)

Average Savings 43% 14%

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Test Results MTM & LTM

Application Clamp Tonnage CycleCompetitive

MachineHydro-

MechanicalHybrid

CompetitiveMachine

Hydro-Mechanical

Hybrid

Industrial Container 1400 990 (30%) 69.0 63.1 (9%)

PC Lamp Bezel 1100 880 (20%) 25.0 20.0 (20%)

Fan Blade 1500 990 (33%) 99.0 80.0 (20%)

Fan Shroud 1000 1000 (0%) 65.0 53.0 (20%)

Infant Car Seat 750 650 (13%) 83.0 63.5 (24%)

Storage Tote 1000 800 (20%) 62.0 44.0 (29%)

Average Savings 19% 20%

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Test Results Summary

95% of applications are tiebar and nottonnage limited

Increasing the tiebar spacing results in:

Lower tonnage machine requirement

Lower energy requirements

Maximized floor space

Faster cycle times

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Efficient Factories

Methodically Implement Innovation

Establish a base of reliable and repeatable moldingequipment

Eliminate external influences on molding processes

Rely on stable and robust infrastructure

Automate to eliminate variation

Establish and maintain Tooling/workcell standards

Quick mold change procedures

Optimal molding recipes

Maintenance procedures

Mold unattended-using SPC to ensure quality control

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Optimize Factory Layout and Equipment

Re-Think the machine cell and factory layout When selecting machines look for ways to improve system

output

Hydraulic services to the mold

Auxiliary power units may be required

Stack Molds

Machine automation

Mold design / maximize cooling

Part Design

Minimize the number of systems required Eliminate secondary operations

Consolidation of Parts

Multi-material

IML

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Efficient Factories

Create healthy work environments

Establish and follow best practices

Environmental health and safety

Air quality Lighting

Noise

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Factory Efficiency-Standard Definition

Overall Equipment Efficiency(OEE) = AT/PT

Overall Factory Efficiency

(OFE) = AT/TT

Unavailable

No work

Scheduleddown

Moldchange

Unscheduled

downtime

Cavities

blocked

Producinggood parts

Factors Impacting Equipment/Factory Throughput

Planned Throughput (PT)

ActualThroughput (AT)

Theoretical Throughput (TT)

Cyclevariance

Producing

scrap

Running

Faulted

Idle

MachineState

Throug

hput

Overall Equipment Efficiency(OEE) = AT/PT

Overall Factory Efficiency

(OFE) = AT/TT

Unavailable

No work

Scheduleddown

Moldchange

Unscheduled

downtime

Cavities

blocked

Producinggood parts

Factors Impacting Equipment/Factory Throughput

Planned Throughput (PT)

ActualThroughput (AT)

Theoretical Throughput (TT)

Cyclevariance

Producing

scrap

Running

Faulted

Idle

MachineState

Throug

hput

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Factory Design as a System:

Maximizes Factory Efficiency

Optimizes equipment utilization

Raises automation levels

Drives process / product consistency

Integrates processes to reduce energyconsumption

Allows for flexibility and easy expansion

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Factory Planning Services

Factory Audits

Manufacturing

Planning

Design &

Engineering

ProjectManagement

ContinuousImprovement

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Factory Audits

Instrument & Analyze existing operations Establish current factory efficiency

Quantify improvement opportunities

Report on findings and recommendations

Compare performance benchmarks

Improvement Area

Opportunity

($/yr) Comments

THROUGHPUT

Efficiency Gains $400,000 OEE Improvement by 5%

Scrap Reduction $100,000 reduction by 1%

Cycle Improvement $400,000 5% improved average cycle t ime

TOTAL $900,000

OPERATIONAL

Labor reduction $560,000 reduction of 4 people per shift

Energy efficiency $125,000 Pump upgrade, chil ler replacement

Inventory Levels $100,000 20% reduction in av. inventory levels

Mold Change Time $150,000 Reduction to 1 hour average

TOTAL $935,000

PLANT SAFETY

Plant Safety $50,000 Reduced WC premiums

TOTAL $1,900,000

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Improvement Opportunities

Plant Assessment Worksheet

Date:______________ Table 1--Rating Plant:________________

Ratings Poor Below

AverageAverage

Above

AverageExcellent

Best in

Class

No Measure Score 0 1 2 3 4 5 Scores

1 Total plant efficiency (TPE) X 4

2Overall Equipment Efficiency

(OEE)

X 3

3Safety, environment,

cleanliness, & orderX 4

4 Scrap rates X 2

5 Equipment reliability X 3

6 Visual Management X 1

7 Level of standardization X 2

8 Resin Handling System X 4

9 Process services X 3

10Product Flow and Use of

spaceX 3

11 Inventories X 1

12 On time deliveries X 4

13 Labor productivity X 2

14 Levels of automation X 2

15 Mold change efficiency X 2

16 Commitment to quality X 2

17Conditions and maintenanceof equipment and tools

X 3

18 Maintenance standards X 2

19 Information Systems X 2

20 Teamwork and Motivation X 2

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Factory Planning Services

Factory Audits

Manufacturing

Planning

Design &

Engineering

Project

Management

ContinuousImprovement

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Manufacturing Planning

Review product matrix, volumes & schedules Compare primary equipment strategies

Define infrastructure requirements

Simulate impact of layout alternatives

Sales and Seasonality

3,000,000

3,500,000

4,000,000

4,500,000

5,000,000

5,500,000

6,000,000

6,500,000

7,000,000

7,500,000

July

Augu

st

Septembe

r

Octob

er

Novembe

r

Decembe

r

Janu

ary

Febr

uary

March

April

May

June

Months

EstimatedMonthly

Volume

Sales 2000-2001

Sales 2001-2002

Ave

Flat Demand

Shipment by Product Category

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TRANSFORMERS

RESIN

SUPPORT

FACILITIES

EXPANSION

FUTURE

MECHANICAL

SHIPPING / RECEIVING

MAINTENANCE

COOLING TOWERS

EXPANSION

FUTURE

ROOM

LINK

PREFORM

STAGING

WAREHOUSEBLOW MOLDING

FUTURE

EXPANSION

HP AIR-COMPRESSORS

IN-LINE

BUFFER

STORAGE

FUTURE

EXPANSION

IN-LINE

BUFFER

STORAGE

SILO

SILO

SILO

HANDLING

ELECTRICAL

ROOM

RESIN

RAIL

CAR

RESINRAILCAR

LINK

SILO

PAD

Finished Products FlowMachine Hall Layout

Supporting AreasRaw Materials Flow

ServicesDistribution

Design Considerations

Primary Equipment

Post Mold Operations

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Benefits of Manufacturing Planning

Define long term strategy to guide shortterm decisions

Quantify the impact of manufacturingalternatives

Benchmark existing operations againstcurrent technologies

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Factory Design as a System

Factory Audits

ManufacturingPlanning

Design &Engineering

ProjectManagement

Continuous

Improvement

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Design and Engineering

Building and process mechanical systems

Resin handling and distribution

Environmental control systems

Mold change alternatives

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Displacement Ventilation +Floor Cooling Using free cooling +Heat Recovery+ Dehumidification

Annual operation costs for different concepts

$0

$50,000

$100,000

$150,000

$200,000

$250,000

$300,000

$350,000

$400,000

SystemA S ys te m B S ys te m C S ys te m D S ys te m E S ys te m F S ys te m G S ys te m H

Operationcosts($/a)

50%

Dehum.


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Benefits of Design and Engineering

Integrate building and molding processrequirements

Lower overall energy consumption

Provide reliability and redundancy Seamless expansion capability

Identity interferences prior to installation

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Factory Design as a System

Factory Audits

Manufacturing

Planning

Design &

Engineering

Project

Management

Continuous

Improvement

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Continuous Improvement Define key performance indicators

Prioritize factory optimization programs

Project manage implementation

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Multi Mold CarrierTechnology

A

1

A

2

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Programmable cranes to automate material handling

Automate to Eliminate Variation

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Area Gantry Robot provides consistency in packaging

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Establish and Maintain Standards

Manufacturing Process - Work Instructions Scheduling

Mold change procedures

Molding recipes

Maintenance practices

Work flow

Tooling / Workcell Designs Runner Systems

Gating

Cavitation

Barrel / Clamp combinations

Quick mold change provisions

Automation

Infrastructure Consistency, redundancy, reliability, seamless expansion

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Workcell Standards

Automation/

Secondary Ops/

Conveyor

AccessAisle(3'-4')

GrinderRawMaterial

Packaging/Accessto Product Aisle

Sprue/

Insert

Controller

ServiceManifold

Drops

ElectricalDrop

Resin

Mo

ldDrop/

StagingArea

Therm'ts

Automation/

Secondary Ops/

Conveyor

Packaging/Accessto Product Aisle

Sprue/

InsertTherm'ts

GrinderRaw Material

PRODUCT REMOVAL ZONE

SERVICE ZONE

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Machine Standardization

4 different machines -Molds dedicated to machine

- average 60% utilization

30% 30%

60% 60% 90%

30%

90% 60%

30% 30% 30%

60% 60%

30%30% 30%30% 30%30% 30%30% 30% 30%

1 common machineMolds flexible to machine

- average 80% utilization

900 [2] 1400 [2]

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WORKCELL STANDARDS

Injection Capacity (cc)

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Case Studies

Water Bottler Medical Thinwall Molder

Custom Molder

PET Preform Molder

Transportation Products

China Factory

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Water Bottler (Asia Pacific)

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Case Study-Water Bottler(Asia Pacific)

Objective: Expand the plant while overcoming major challenges such as:

Remote location

Logistics for shipping high volume output

Lack of electrical and sanitary infrastructure

Approach: Develop long-term manufacturing strategy and implementation

plan

Results:

Seamless expansion capability

Self-generating power facility (Cogen ready with expansion) Bio-filtration system

Closed cooling system to eliminate losses from evaporation

Plant and infrastructure layout allowing 10 times more output

Delivered a 110,000 Sq/ft facility in less than one year

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Medical Thinwall Molder (North America)

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Case Study-Medical Thinwall Molder(North America)

Objective:

Launch a new line of products in response to off-shore pricingcompetition

Approach:

Upgrade the existing facility to realize performance capabilities

of new machinesResults:

Optimal plant layout allowing workcell automation

Detailed specifications for floor slabs, process infrastructure andoverhead cranes

Plant upgrades completed in eights weeks

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Custom Molder (North America)

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Case Study-Custom Molder(North America)

Objective: Design a low-emissions facility which incorporates energy

conserving technologies

Approach:

Photovoltaic cells generate 45 KVA of electricity

Natural ventilation and day lighting, displacement ventilation,waste heat recovery, in-floor radiant heating and cooling

Treatment of all waste water through biological filters

Results:

Manufacturing flexibility was assured with a machine hall free ofcolumns

Infrastructure and material handling were distributed through afull basement

Facility maximizes efficiency with the integration ofmanufacturing automation, building technology and energyconservation

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PET Preform Molder (North America)


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Case Study-PET Preform Molder(North America)

Objective: Construct a high output preform manufacturing center in six

months

Approach:

Established layout and technical specifications

Created master schedule that outlined critical equipment andconstruction elements

Centralized dehumidification system

Unique (small volume) molding hall design

Results:

Molded first part 6 months after kick-off meeting

Coupled HVAC and process systems to optimize energyconsumption

3D process system design allowed pre-fabrication of pipesections reducing installation time-ready for seamlessexpansion

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Transportation Products (North America)

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Objective: Launch new injection molding product line to replace SMC

thermoforming

Approach

Convert existing small foot print, light duty manufacturing facility

to high performance molding operation

Result:

Process mechanical system designed and delivered in a pre-fabricated, insulated enclosure outside the building envelope

Floor slabs replaced to support up to 1000 ton machines

Over head crane allows safe quick mold change and handling

Project completed prior to six month launch deadline

Case Study-Transportation Products(North America)

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Energy ConceptSummer Mode

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Factory Planning

2003 Husky Injection Molding Systems LTD.

Maximizing Factory Efficiency

Documents

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