Mold Maintenance & Repair

OCT 2015

Mold Maintenance & Repair

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October 2015 13 says, a culture in which maintenance is viewed as an opportunity to improve—that is, to save the customer money—drives trainees to not just go through the motions, but to constantly query their seasoned mentors and seek any opportunity to apply their burgeoning skills. In the meantime, a well-honed approach to maintenance helps ensure the right questions get asked with or without a trained eye. It also ensures that veterans and trainees alike learn from past experience. Along with the sort of investigative mindset described above, this is how tooling wear truly becomes predictable, Klingler says, and how maintenance truly be- comes an exercise in continuous improvement. The Improvement Loop The basics of Janler's process are outlined in the generic preventive maintenance checklist on the left, which serves as a learning and sales tool ("generic" because specifc procedures vary from tool to tool). Similarly to a pilot going through a pre-fight checklist, personnel are expected to sign off on every step to ensure due diligence and accountability. Perhaps even more important is the fact that the majority of process steps include instruc- tions to record fndings, which are then scanned into the company's JobBoss enterprise resource planning (ERP) system. All activities resulting from a mold investigation, from replaced com- instance, customers requesting emergency re- pairs are typically instructed to put the mold on a skid and ship it exactly as is, without so much as a cursory wipe-down, to avoid destroying evidence. PM is likewise treated more like an investigation than a series of rote tasks to complete. "If you're just blindly going through the process of taking a mold apart, cleaning and relubing, and putting it back together, you might be doing maintenance, but you're not doing preventive maintenance," Klingler says. "We are always looking deeper, trying to get to the bottom of anything that looks peculiar." Do those fret marks indicate uniform pressure across the parting line? Why is cavity four wear- ing differently than cavity 36? If that vent is still within specifcation, why is there gas buildup? Is the vent dump blocked? If so, why did that hap- pen? Asking these sorts of questions not only helps prevent problems before they happen, but also accelerates the development of the apprentices mentioned earlier. After all, Klingler The fact that the bottom of this cavity insert isn't completely flat indicates that repeated cycles have begun to collapse the vents. Knowing precisely when this will show up in the plastic can affect everything from maintenance intervals to inventories of spares. Images courtesy of Janler Corp. Janler's Preventive Maintenance Checklist • Evaluate molded plastic part samples, record defects. • Visually inspect corresponding steel conditions, record defects. • Disassemble for cleaning. • Visually inspect molding surfaces, record defects. • Check molding component surface fnishes under magnifcation, record defects. • Visually inspect plating, chemical-test suspect components, record defects. • Check and record vent depth with mechanical indicator. • Visually and mechanically (CMM) inspect ejec- tion guide pins/bushings, record fndings. • Visually and mechanically (CMM) inspect leader guide pins and bushings, record fndings. • V isually inspect parting line/shut-offs, record defects. • Inspect ga tes with mechanical pin gage, record fndings. • Mechanically (CMM) inspect parting line locks, record fndings. • Visually inspect vlier pins/springs/retainers, record defects. • Pressure test and fow water line circuits for leaks. • Visually inspect runner and sprue, record defects. • Check t emperature of all hot runner circuits, record fndings, replace worn/damaged tips.

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