Mold Maintenance & Repair

OCT 2013

Mold Maintenance & Repair

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Performance and Maintenance Data (broken down by chosen timeframe): 1. What are your top 10 unscheduled mold stop reasons? (Unscheduled downtime) 2. What are your top 10 part or product defects? (Loss of production/mold cavitation) 3. What are your top 10 mold frame issues? (Issues with the mold – not the part) 4. What are your top 10 molds with the highest maintenance costs per hour? (Tooling and labor used per hour or cycles of run time) 5. What is your "on time" PM percentage based on your own company/shop goals? 6. What are your top 10 worst performing molds based on cavitation? (Number of cavities blocked) 7. What are your top 10 worst performing molds based on cycle time efficiency? (Standard vs. Actual) 8. What are your top 10 molds with the highest overall defect counts? 9. What are your top 10 molds with the highest overall tooling usage? 10. What are your top 10 molds with the highest overall labor requirements? Most shops, as a minimum, can quickly gather data concerning monies spent on tooling and labor. But this is only a very small part of the picture. If you want your molds to run reliably, producing the highest quality parts with the least amount of unscheduled downtime possible, then you must take the typical data that most shops collect and input it into a system that will present it back to you in a format that will allow complete utilization of it. It just does not make sense, nor is it cost effective, to spend time collecting data that you cannot use, is vague or inaccurate. So if you spend time collecting data, why not use it? gedwed, "we took the time and put a few dollars into the mold because we were able to justify not having further cavity shutofs or mold stoppages ahead." "it's the 'pay me now or pay me later' scenario," says Keith. "Many times there are pennies-on-the-dollar opportunities for a mold to get up to performing how it was originally intended to. We've seen it where, more than just disassemble, clean and assemble, we've sent out a mold frame for cleaning and nickel plating, completely rebuilt cavity inserts that have been frequent fash points, and replaced some originally made lifter components with more reliable, standardized tooling. Many times it's better to bite the bullet and reinvest in the tool and change the cost course that it's on." but the actual maintenance and mold performance costs need to be justifed to get this done. "When you can look at the money going into the corrective actions and lost production you then become truly data-driven," states gedwed. "so by using the data to make decisions, you start to fx things and become less reactive. The end result is that you save money and feel confdent knowing that the problem won't repeat." Furthermore, it's not just the cost of maintenance and spare parts replacement. other ramifcations can result like late shipments and quality issues in the feld that can threaten relationships and confdence with customers. i'd wager that uPs and Fedex would be able to calculate accurately what it would cost them if their feet of trucks were on the side of the road with their hoods up. similarly, we have to calculate accurately the cost of maintaining our feet of tools in order to make proftable decisions. in a perfect world there would be no such thing as mold repair—only proactive maintenance. Molds would run and be maintained in such a way as to never break down or make bad production while maximizing tooling life. However, in the real world, advancing from a mold repair culture to a mold maintenance culture can only be fully supported by beginning with a companywide understanding and agreement on what the real costs are and what the real potential savings can be—and then setting one's course for that target. COnTRiBuTOR: Steve Johnson is Operations Manager for ToolingDocs. For More Information: ToolingDocs / (800) 257-8369 / toolingdocs.com October 2013 7

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