Selection. Selection. Service. The ARBURG Magazine. CONTENT Selection Service 07/2010

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1 The ARBURG Magazine Service Selection CONTENT Selection Service 07/2010 MASTHEAD Fast set-up times efficient production An individual approach to technology training! Retrofitting energy-efficiency? A sure eye for maintenance Total access Assuring quality Only ARBURG service is original Oil management counts Machine inspection and certification Active spare parts management Strong together Smooth running Service around the clock - Issue 43 - Issue 43 - Issue 42 - Issue 42 - Issue 33 - Issue 37 - Issue 38 - Issue 37 - Issue 30 - Issue 29 - Issue 28 - Issue 32 - Issue 25 today, the ARBURG magazine Reprints, including excerpts, may be made with permission only. Responsible: Matthias Uhl Editorial advisory board: Oliver Giesen, Juliane Hehl, Martin Hoyer, Herbert Kraibühler, Bernd Schmid, Jürgen Schray, Wolfgang Umbrecht, Renate Würth Editorial team: Uwe Becker (text), Markus Mertmann (photos), Susanne Palm (text), Oliver Schäfer (text), Vesna Sertić (photos), Peter Zipfel (layout) Editorial address: ARBURG GmbH + Co KG, PO box 1109, Lossburg, Germany Tel.: +49 (0) , Fax: +49 (0) today_kundenmagazin@arburg.com,

2 TECH TALK Dipl. Ing. (BA) Oliver Schäfer, Technical Information Fast set-up times Small series, different product versions, just-in-time production and delivery, these are the requirements which increasingly face injection moulding companies. These result in frequent changeover procedures, when machines stand idle and fail to return a profit, even though they continue to consume energy. Time literally becomes money. In order to produce flexibly, energy-efficiently and competitively, short set-up times are essential. This can often be achieved without major investment. significantly by placing one technician at the front and one at the rear of the machine. This applies particularly if you consider how often a single technician has to walk around the machine during the setup procedure (see diagram). A standardised clamping system should be chosen when designing the tools. It is important that the clamping platens are of the same size when the moulds are mounted directly. This allows you to use the same bolts throughout. Work can be made even easier by using clamping elements that remain attached to the machine and that can be used flexibly for other moulds. If a large number of in-house moulds are used, it is advisable to standardise the clamping platens. In combination with mechanical rapid clamping systems such as the one provided by ARBURG, moulds can be changed in just a few minutes. Ideally, a power-adapted temperature control Perfect preparation as the previous job is still running is of crucial importance for a fast changeover. Checklists help ensure that nothing, for example the appropriate hoses, is forgotten. In addition, a well-organised cart with all the required tools and bolts should be available prior to every setup. This means that everything is in place as soon as the machine stops. Nothing needs to be searched for or fetched. After all, every unnecessary journey wastes time. A decisive time factor during the changeover procedure is the actual changing of the moulds, particularly in the case of larger machines. Distances, and therefore the time expended, can be reduced Quality assurance 4 x 4 m Material box 4 x 40 m Fetch hose Servicing Mould 4 x 10 m 4 x 40 m 4 x 3 m 18 x 6 m 6 x 3m 14 x 2 m Tool cart 9 x 4 m 5 x 7 m Total: 701 m 6 x 2 m 5 x 14 m 4 x 5 m Machine cabinet Source: Fischer Consulting 2 today 43/2010

3 efficient production unit should be permanently assigned to a machine so that set-up can be performed in a straightforward manner in conjunc tion with standard rapid connect couplings. The next step in increasing efficiency is the standardisation of the entire setup process. After all, in the absence of a precisely defined, systematic set-up procedure, every employee will determine his own. In this case, optimisation often becomes a secondary concern. If, on the other hand, all employees follow the same standard, frequently practising and improving it, machine downtimes can be significantly minimised. Employee training is particularly important. After all, this measure will help in implementing speedy set-ups more effectively than any investment. In many cases, the intensive involvement of employees also brings about an increase in innovations, resulting in a continuous improvement process. Forward-thinking, machine-based production planning is essential if installation technicians are to organise their work to optimum effect and achieve short set-up times. Production management systems with online entry of machine and order data such as the ARBURG host computer system (ALS) ensure the necessary transparency in production and facilitate detailed planning on the basis of current, reliable data. Further measures aimed at reducing set-up times include the use of a preheating station for moulds and the provision of several cylinder modules. The advantage of the latter when changing colours to a completely transparent material is that the sometimes very timeconsuming cleaning work can be omitted. ARBURG has always worked to keep set-up processes as simple as possible. This is demonstrated by several ALLROUNDER features such as the ejector rapid release coupling, media connectors positioned on the machine s clamping platens, swivelling injection units, central coupling of the cylinder module and the second program level of the SELOGICA control system. If one considers the many opportunities for optimising the set-up process, there is still a lot of untapped potential in many injection moulding companies. Experience shows set-up time reductions of up to 50 percent are not unusual. Investigations have revealed that the distances travelled during set-up can sometimes be considerable (see graphic on left). Minimising these distances represents a key step in reducing set-up times today 43/2010 3

4 An individual approach Again and again, surveys and statistics confirm what we have already known for some time in Germany and Europe: We live and work in a high-wage region and must take appropriate steps to ensure our international competitiveness. Consequently, automated production cells are increasingly being used in plastics processing in order to produce cost-effectively in large-volumes. For this purpose, complex machine and control system technologies are required whose potential must be exploited in full in order to achieve consistent quality and efficiency. To this end, ARBURG is offering individually tailored training programs held directly at the customer s premises. Offenau-based company KWO has made extremely positive experiences with this offering to date. Since the management buy-in in 2005, Kunststoffteile GmbH Offenau has been managed by Dr. Michael Jauss and Matthias Wendler as owners. The development of the company, which Matthias Wendler describes as an organic growth of 60 percent between 2005 and 2008, has seen sales rise to 16 million euros in At its location in Offenau near Heilbronn, KWO deals in the manufacture of moulds and high-volume part production. 80 percent of production is accounted for by the automotive sector, with a further 20 percent in the consumer products sector. The company s customers are located in Germany, Hungary, Czech Republic, France, Belgium, Switzerland and the UK. KWO intends further expansion in the future, says Wendler. At present we have a production area of 3,000 square metres and we already have building permission for a further 1,500 square metres. The production halls house a total of 40 injection moulding machines, 30 of which are from ARBURG. These include both rotary table machines and electrical and hydraulic ALLROUNDERs, some of which are equipped with corresponding MULTILIFT robotic systems. Wendler assesses the cooperative relationship between KWO and ARBURG, which has existed since 1981 when the company first began injection moulding production, as being good and reliable: Pricing and scheduling are reasonable and response times are pleasantly short. Injection moulding machines and robotic systems can be integrated very successfully in our production environment. We see great promise in the technology used in the ARBURG host computer system ALS and will soon introduce this. Naturally, repairs to injection moulding machines are an ongoing issue and are always a problem. However, this is not something that solely affects ARBURG. Because all ALLROUNDER machines are equipped with the universal highperformance SELOGICA machine control system, it quickly became clear that it would make sense to provide employees with in-depth training on making the best use of all the options provided by this control system and consequently of the machine technology as a whole. ARBURG therefore devised an individually tailored two-year training package for KWO that would each month focus on the challenges currently faced by the company and deal with them in terms of the control system and injection moulding technology. The training days begin with a discussion on pending issues at the management level. Depending on requirements, the installation technicians who are to receive the individual training also attend. The focus is mainly on general issues relating to machine and control system technology. Among the issues discussed are the possibilities in relation to forthcoming operational projects with ALLROUNDERs 4 today 43/2010

5 to technology training! extremely important: We consider this training crucial in order to exploit the full potential of ARBURG machines in practice in our company. Following the conclusion of the first year of training, we were proven right in our opinion that these courses were worthwhile, particularly in terms of the quality of parts production and the efficiencies achieved. And how do the trained employees view the program at the half-way point? The answer could hardly be more concise or decisive: Excellent! Owner Matthias Wendler (centre) is delighted with the success of the ARBURG training courses, performed directly on the ALLROUNDERs (right). Detailed discussions (left) ensure that the contents are perfectly tailored to KWO production. INFOBOX and the options required in order to meet these requirements. Following the meeting, the training moves into production, where the agreed agenda is gone through with the relevant training course participants and the available procedures and options with regard to the machine and control system are explained. The day ends with a final meeting in which the achieved results are discussed. As the course progresses, all the process engineers thus receive at least one day of intensive on the job training. Matthias Wendler believes that this training is Founded: 1971, 2005 management buy-in Products: Engineering, moulds and parts, in particular high-precision parts, such as connectors for control system electronics, micro injection moulded parts, LSR two-component parts and complex assemblies made from PA, PBT, PPA, PPS, LSR, LCP, TPE, PC, PP Quality assurance: ISO 9001, TS 16929, ISO 14001/EMAS in the first quarter of 2010 Employees: 140 Contact: KWO Kunststoffteile GmbH Talweg 9-13, Offenau, Germany today 43/2010 5

6 TECH TALK Dipl. Ing. (BA) Oliver Schäfer, Technical Information Retrofitting energy- Energy-efficiency is currently a much-debated topic, for injection moulding companies as well. As an innovative injection moulding machinery manufacturer and pioneer with regard to energy efficiency, ARBURG is confronted with an ever growing number of enquiries on a daily basis. In addition to selecting the right machine concept for new purchases, there is now increasing focus on retrofitting energy-efficient technology on older injection moulding machines. However, in many cases, the potential for energy savings achievable through retrofitting is insufficient to warrant the sometimes extremely high conversion costs. This applies especially to small and medium-sized injection moulding machines. The reason is that the energy requirements and therefore the potential for savings decrease the smaller the machines are (see chart). In contrast, retrofit and conversion costs are largely independent of the machine size. Examples of this are the retrofitting of an electric dosage drive or speed controlled pump motor on hydraulic machines - regulating pumps have been the standard in ALLROUNDERs for over 30 years. During conversion, the control system and software must also be upgraded. This entails not only the considerable cost of new components such as frequency converters and motors, but also the associated labour costs. Owing to the high conversion costs, these retrofitting measures are therefore seldom economically viable. The situation is quite different if the energy-efficient equipment is ordered directly when the in jection moulding machine is purchased. In this case, the higher investment costs incurred are significantly reduced due to the absence of the conventional components. The same applies to the retrofitting of energy saving motors of the highest efficiency class, EFF1. In comparison with a conventional EFF2 motor, energy savings of up to four percent can be achieved, but the greater energy-efficiency alone is not sufficient to justify the replacement of existing motors. However, if a faulty motor needs repairing or replacing, it may certainly be worth considering the alternative EFF1 motor. The available installation space is also decisive because energy-saving motors are larger than EFF2 motors. A further retrofitting option is to fully Cost savings / year Electric dosage drive Speed-regulated pump motor Basis for calculation: typically equipped machines with half material throughput at 6,000 operating hours per year and an electricity price of EFF1 pump motor Fully insulated cylinder module Machine size 6 today 42/2010

7 efficiency? insulate the cylinder module of the injection unit. This allows the heat dissipation losses to be reduced to a minimum. However, all insulation also represents an intervention in temperature control and must consequently be designed with the relevant application in mind. The viscosity of the processed material and the material throughput play a decisive role here. Despite all considerations with regard to efficiency, however, a controlled, reproducible process must always be the priority. A compromise between energy saving and process stability is the standard insulation of the cylinder modules on ALLROUNDERs. Heat loss through radiation is already significantly reduced, while at the same time ensuring a more controlled, more reproducible process. Nevertheless, it is always recommendable to consider the option of full insulation. Additional potential is said to be achievable through decentralised reactive current compensation directly at the injection moulding machine. However, most injection moulding businesses already use centralised reactive current compensation systems. These are generally more than adequate. The currently available low-viscosity multigrade hydraulic oils also generally permit energy savings. The extent of the potential savings on a particular machine, however, ultimately depends on a number of influencing factors, for example the injection moulding process and the type of hydraulic drive. Consequently, only an individual comparison generally proves meaningful. The energy savings achieved by means of low-viscosity hydraulic oils must be balanced against higher purchasing costs and, in the case of retrofits, the costs for changing the oil in the injection moulding machines. Bear in mind, however, that the use of these hydraulic oils is not always permissible on account of their low viscosity, particularly in the case of older pump systems. The examples described show that the retrofitting of already installed injection moulding machines for the purposes of energy efficiency is a complex task which often fails to live up to expectations. However, the potential for energy savings in production organisation is often completely neglected. This is despite the fact that such measures can usually be implemented directly without any additional costs. A good example of this is standby mode. This standard function of the SELOGICA control system means that you can help save energy by simply pressing a button, for example during breaks or downtimes. Whether standby mode only involves switching off the pump motor or whether cylinder and mould heating are lowered can be easily programmed in accordance with the moulds being Energy efficiency: switch-on to switching-off (top). The energy-saving potential of retrofitting measures (chart on left), however, is often insufficient to justify the conversion costs. used. Another interesting feature of the SELOGICA is the automatic switchover to standby mode if the control system does not register machine movements during a freely programmable period. Training and awareness-raising of employees should therefore always be a central component of energy efficiency activities. today 42/2010 7

8 A sure eye for maintenance A prerequisite for the permanent availability and reliability of an injection moulding machine is careful and regular maintenance. To ensure that nothing is left to chance during routine production, the SELOGICA direct machine control system features a user-friendly maintenance program - including continuous monitoring of due dates and automatic reminders for forthcoming maintenance work. Depending on the configuration of the relevant ALLROUNDER, all the necessary maintenance tasks and intervals are already specified in the control system in plain text form. As an option, further individual maintenance specifications, relating for example to moulds or additional peripherals, can be entered manually. Finally, the SELOGICA can be used to generate a clear maintenance plan for the entire production unit, which always provides information on when the various maintenance tasks are due. The due date for the recorded maintenance work is continuously checked according to operating hours, machine cycles or months. A separately adjustable early warning threshold also provides information about pending maintenance tasks, ensuring optimum planning and preparations. If a maintenance interval is accidentally exceeded, the machine does not stop immediately, but continues to operate until the batch has been completed or until the next manual stop. However, in order to restart the machine, the correct completion of the pending maintenance work must be confirmed in the SELOGICA system. The control system logs and saves every acknowledgement in a so-called maintenance log. As a result, every maintenance completed remains fully transparent, also providing ideal verification for audits and certifications. In principle, all standard maintenance tasks on ALLROUNDERs can be carried out by the operator himself in accordance with the operating manual. With inspection contracts, however, all important machine elements are inspected for wear, operability and safety by an ARBURG service technician on a regular basis. From October 2009 onwards, ARBURG will also provide training courses on Preventive Maintenance. These courses can also be tailored to the needs of individual customers and provided on their premises. A customerspecific training course of this type makes it possible to combine injection moulding You will find all maintenance-related information in a clearly-organised overview on the relevant SELOGICA screen pages. theory and practice to optimum effect, and to directly exploit the resulting potential for improvement. 8 today 42/2009

9 Total access The production volumes are getting smaller, the deadline constraints are becoming tighter: in order to meet these demands, the capacity and flexibility of the machine fleet must be optimally utilised. This is where the ARBURG Remote Service (ARS) software comes in, which enables remote access to the control systems of the ALLROUNDERs via PC. With ARS, the production time and machine downtime of the ALLROUNDERs can be monitored. Akin to a tachograph, the ARS records the machine status and displays it clearly in chronological sequence. For instance, the production sequence during a shift can easily be analysed. Based on current machine and production data, it is possible to determine via ARS, which jobs are running on the machines and to what extent these have been completed. The progress of production can be monitored transparently at a glance for production planning purposes. In order to react quickly to impending deadline violations, ARS also enables the transfer of machine programmes from one machine to another. A further feature is the option to display and print out individual screen pages. The current production process can thus be analysed and documented at all times. Consequently, a centralised user support system including remote diagnosis or remote maintenance via ARBURG Customer Service can be provided. For protection of the production data, it can be determined explicitly which users have access to what machine via the ARS user and machine management system. When setting up an ARS, the internationally recognised Ethernet networking standard is employed, which is also used for PC networking. For connection of an ALLROUNDER to the network, it must be equipped with the ALLROUNDER@web machine interface. The ARS software is installed on the central PC in the network. Machine and production data can then be accessed from any other PC connected to the network. Remote production locations or facilities can also be accessed via existing network connections so that production there can be monitored at the click of a button. The performance of ARS can be tested using the demo version at arburg.com/ars. In addition to ARS, ARBURG also offers its customers the ARBURG host computer system (ALS), the functionalities of which extend far beyond those of the ARBURG Remote Service. The ALS basic module for machine and operating data recording can be flexibly adapted to the specific operating requirements through mutuallycompatible expansion modules. The functionalities of ALS can thus be expanded far beyond the conventional BDE or MES systems. Even connection to production planning systems (PPS or ERP) can be realised. Remote access to the ALLROUNDER screen pages (centre) is possible via ARS and the ALLROUNDER@web machine interface (above right). today 33/2006 9

10 Assuring quality Capability validation serves to assess machines and production processes with regard to quality considerations. But in the field of injection moulding, in particular, opinions can differ widely as to what machine and process capability ultimately mean. Clear definitions are therefore vital for all concerned. The quality capability of an injection moulding machine depends primarily on the precise operation of its measurement and control systems. This can be ensured through the calibration of all quality-relevant machine parameters during dry runs, i.e. operation without mould or material. Calibration of this type is performed on every ALLROUNDER prior to delivery. However, because machine parameters may change over time, for example through wear, regular re-calibration is necessary. The calibration of injection moulding machines is based on guidelines produced by the VDMA (German Engineering Federation). Only in this way can the reproducibility of an injection moulding machine be maintained. ARBURG offers inspection contracts for this purpose. A quality-capable injection moulding machine is the first prerequisite for ensuring moulded part quality. But parameter settings, the mould, cooling, temperature control as well as the material, operator and environmental conditions also have an influence on moulded part quality. In order to prove the process capability of an injection moulding machine, moulded parts must therefore also be produced and specified characteristics and tolerances checked. Process capability is divided into two stages, depending on the environmental conditions and the timeframe of the investigation. The first stage is so-called short-term capability, in which only a small number of consecutively produced moulded parts are examined. Due to the short testing period, influences owing to material, operator and environment remain virtually constant. The result therefore permits a basic statement on the quality capability of the production facility and is consequently referred to as machine capability. Machine capability is usually verified during acceptance testing at the factory using the customer s mould and materials. If customers so wish, ARBURG can provide assistance in the determination of tolerances and the statistical analysis of individual process parameters. Statements on the actual process capability, however, can only be made once quality capability is examined under real process conditions. Tests of this kind must necessarily be performed on site and over an extended period, so that influencing factors such as the material, operator and environment can take effect. Here, the ARBURG quality assurance system AQS can provide assistance. 10 today 37/2008

11 Only ARBURG service is original What applies to ARBURG s machines and spare parts applies equally to the company s entire range of services: customers are only covered by a full warranty if their ALLROUNDER injection moulding technology is serviced by ARBURG specialists. You don t hand your car to your neighbour for an MOT, do you? You go to an authorised, specialist repair shop. Even if you ve read otherwise elsewhere, you can only get original ARBURG service from ARBURG. For of course, ARBURG cannot take responsibility for work carried out on ALLROUNDERs by unauthorised third parties. This applies both to the parts used and the service itself. But not only can inexpert repairs cause If you want perfect maintenance and repairs and high machine availability, it s best to rely on ARBURG service. warranty claims to become invalid, they can have much worse consequences - such as machine failure. In that case, rapid assistance from ARBURG specialists cannot necessarily be taken for granted, for if service work has been handed over to third parties, then of course the service documentation supplied with every machine will be incomplete. And as a result, there may be problems with the hotline service and machine calibrations, incorrect diagnoses may be made or the wrong parts delivered. In other words, it may simply take longer to locate the fault and remedy it in the proper manner. Basically, the road to inexpert services is extremely easy, which makes it all the more problematic: independent engineers and service technicians have not benefited from ARBURG s training in the latest injection moulding technologies and therefore cannot possibly possess the solid expertise of ARBURG specialists. So, getting repairs done in this way always entails a risk. For this reason, for all ARBURG customers it really matters to whom they contract their services. For what seems cheaper at first can ultimately turn out to be an expensive mistake. On the other hand, customers who work not just with the ALLROUNDERs but also with ARBURG s expert service can access and place their trust in an extensive range of services. Our offer ranges from a 24-hour hotline to in-depth training courses on machines and technology, preventive maintenance via service contracts, our oil service, a comprehensive spare parts service, technical advice and finally, the rapid handling of all warranty claims. In this area, too, ARBURG s good reputation didn t come about by chance. ARBURG offers Service allround - and in the long term, that always pays off! today 38/

12 Oil managem In addition to improper maintenance, contaminated hydraulic oil is one of the principal causes of faults in injection moulding machines. In 70 to 90 per cent of cases, damage to hydraulic components is attributable to contamination in the hydraulic system. The goal of oil management is to prevent contamination of this kind in order to enhance the availably, reliability and therefore the efficiency of injection moulding machines. Oil management is not restricted to the end user, it also involves the manufacturer of the injection moulding machine. Hydraulic oils can become contaminated through air, water or solid particles. It is contamination by solid matter that is the primary cause of significant surface damage to hydraulic components through wear mechanisms such as abrasion. The consequences are control inaccuracies, leaks, losses in efficiency and a shorter service life of components. More and more particles penetrate into the hydraulic oil and wear is further increased. Even filter systems can only interrupt this chain reaction of wear to a limited extent. In addition to the number of particles, their size also has a decisive influence on wear. The wear-inducing particles are so small that they cannot be detected by the naked eye. In order to achieve a reproducible classification of particulate contamination in hydraulic oils, several standardised methods of analysis are available. The international 12 today 37/2008

13 ent counts ISO 4406:1999 standard is widely used, in which the number of particles larger than four, six and fourteen microns respectively is determined and assigned to a defined characteristic value. In practice, automatic particle counters are normally used for this purpose. The purity of a hydraulic oil can thus be assessed very quickly and simply. It should be noted that the increase of a characteristic value by a factor of one represents a doubling of the number of particles. But how do hydraulic oils become contaminated in the first place? First of all, a lack of cleanliness with regard to components during assembly is worthy of mention. This so-called original or initial contamination of the hydraulic system can have a decisive effect on the reliability of an injection moulding machine. As a rule, the lower the degree of original contamination, the more wear-free the hydraulic system will initially be. Consequently, oil management always begins with the manufacturer. A further important source of contamination is the hydraulic oil itself. The required purity class of the oil is determined by the hydraulic system: The higher the performance requirement of the parts used, the greater the demands. ALLROUNDERs require purity class ISO 18/15/12. Conventional drum oil does not meet this standard. The seriousness with which ARBURG regards the subject of oil management can be seen in all areas of production. Prior to assembly, for example, cast parts such as the housing or cylinder covers are freed of soiling in so-called washing machines. Once cleaned, all the components are kept in closed boxes or under protective film until they are installed. A similar procedure applies to the hydraulic pipes and hoses, which are rinsed out and then protected from soiling by means of plugs. ARBURG also commissions all the injection moulding machines before they leave the factory. The purity class of the hydraulic oil used for this purpose is regularly monitored and is significantly above the requirements. The oil tank is vacuum evacuated following commissioning. All these efforts on the part of ARBURG would however be nullified without the end user s co-operation. For example, if hydraulic oils that do not comply with the specified purity class are used in ALLROUNDER machines. Proper storage of the hydraulic oils is decisive in order to maintain their purity class. Hydraulic oils should also always be filled via a micro-filter unit. If these measures Cleanliness is a priority at ARBURG: for example, components are kept in closed boxes until assembly (photo, top left), and the oil tank is vacuum evacuated prior to delivery (photo, top right). The oil tank should always be filled via micro-filter units (photo, centre). Microscopic photographs (bottom left: Pall Corporation) clearly demonstrate the differences in quality of hydraulic oils (ISO 18/15/12 and 21/20/17). are not observed, contamination of the hydraulic system will automatically occur. In this case, preliminary damage and even the premature failure of hydraulic components is virtually pre-programmed. The final step in effective oil management is the regular performance of oil condition analyses. These permit the reliable detection of unusual contamination of the hydraulic oil. Conclusions can therefore be drawn with regard to wear on pumps and seals, for example. today 37/

14 Machine inspection In addition to the machine exhibits at the Fakuma, ARBURG will also be presenting its complete range of services at its stand-in-stand. The new inspection contracts, which include a certificate and an inspection stamp of approval, are the focus of our technical service. Thanks to the modular structure of the service, the inspection intervals and the scope of inspection can be determined individually according to the requirements of the customer. Because inspection plays an important role in many certification processes, ARBURG has been offering its customers inspection contracts for a number of years now. As outlined in these contracts, ARBURG service technicians check all key elements of the machine for wear, correct function and safety at defined intervals. This also includes the inspection and, if necessary, recalibration of all machine and control parameters that relate to quality. In order to offer its customers tailormade solutions that meet a variety of quality standards, the new inspection contracts are designed in a modular format. The basic inspection includes the calibration of parameters relevant to the injection moulding process and can also include the recording of actual values as an option. Additional options include an evaluation of displacement measurements, an inspection of the mould platens for parallel alignment, with or without recording actual values in each case, testing the and certification At the Fakuma 2003, the service department had its own presen - tation forum within the ARBURG stand (above). Among other items to be presented here in 2005 will be the new inspection contracts (right). pressure inside the mould as well as the temperature measurement chain inside the cylinder and also in the mould, calibration of auxiliary control valves, a general inspection, a check of the protective guards and also an oil analysis by an independent laboratory. Approval tests can also be performed at the factory for new machines. These inspections can be performed in intervals of one or two years, depending on the requirements of the customer. The customer then receives updated digital documentation for each inspected machine, in which the results and measured values for up to five inspections are logged and documented in detail. Within the scope of certification, for instance, this can serve as proof of preventive maintenance. In future, customers will also receive an official ARBURG inspection certificate as well as inspection badges for each machine. In order to further illustrate the inspection process for visitors at the Fakuma, a service technician will explain the various inspections and measurements live on an ALLROUNDER 170 U. 14 today 30/2005

15 Active spare parts management Personalised customer support has been high priority at ARBURG for a great many years. This has been further enhanced by the introduction of active spare parts management (ASM). This includes extensive consultancy services, a high level of spare part quality and availability with a fair price/performance ratio, as well as customised maintenance and expendable parts packages. The aim of ASM is to reduce downtimes and therefore costs by means of proactive planning. An important factor is extensive, personalised consulting. Depending on the machines used and the materials to be processed, ARBURG supports its customers with advice and assistance and helps them select the suitable components. In this way it is often possible to rule out production problems from the outset. In order to minimise production downtimes, various maintenance and expendable parts packages are put together for the customers, which are tailor-made to the relevant machine fleet. An important aspect of this is the guarantee of being able to subsequently purchase spare parts for older machines. The high degree of spare part quality and availability is ensured by the in-house production at the headquarters in Lossburg from development to series production. Thanks to constant investment in modern production facilities and processes, ARBURG is able to offer quality products with the best possible price/ performance ratio. The costs, for instance, of complete cylinder modules and of individual screws and cylinders have been considerably reduced through optimised screw production processes. Those wishing to achieve additional cost savings can procure spare parts packages at Well attended - the Service presentation forum set up especially for the Technology Days. favourable conditions. Furthermore, the high degree of spare parts availability in conjunction with a sophisticated in-house logistics system guarantees fast shipment of spare parts. today 29/

16 Strong together Two target groups one target: Both customers and ARBURG service engineers alike make use of training courses to familiarise themselves with the details of the ARBURG products and to enhance their knowledge of injection moulding. Combining training for customers and internal service engineers under one roof seemed the most logical consequence. And this is exactly what ARBURG did some time ago by assigning both training schemes to the new Product Training department. At first glance, merging customer training and internal service-engineer training might not appear to have changed much. However, a look behind the scenes quickly reveals the decisive advantages of this approach. Uwe Klumpp is the central contact person responsible for co-ordination of the entire training department. As there are experts with many years of practical experience working in customer training as well as in service-engineer training, they can now be deployed flexibly and effectively in both departments. Response to customer s requirements is quick, and specially tailored courses can also, for example, be provided at the customer s premises. As a result of the expansion of the Product Training department, the team now numbers 17, and rising. The group of 14 instructors includes plastics engineers and process engineering technicians for plastics and rubber technologies, from mechanical engineers through to electrical engineers and technicians. The entire spectrum of injection-moulding technology is thus covered by appropriate specialists, including the areas of rotary table machines, multi-component injection moulding, powder injection moulding, thermoset processing and the ARBURG host computer system (ALS). In terms of machinery and robotic systems, the team in Lossburg is very well equipped with various ALLROUNDERs and MULTILIFT robotic systems which are available exclusively for training purposes. In order to ensure that all the ARBURG service engineers around the world are highly trained and possess in-depth expertise in the areas of injection moulding technology and ALLROUNDER technology, they all undergo standardised training in Lossburg. This also benefits the customers who receive the same The Product Training team around Uwe Klumpp (front right) is made up of experts from a variety of fields, who train the internal service engineers as well as customers on all ARBURG products. comprehensive knowledge relating to the ARBURG products when they attend training courses. The advantages of the joint Product Training department are also evident with regard to new products, as the service technicians receive early training on them. Thanks to standardised training documentation, compiled by the instructors and later to be made available in digital, animated form, the range of customer training courses on offer can be extended very quickly. 16 today 28/2005

17 Smooth running Today, increased productivity plays a significant role when it comes to competitiveness and cost savings. For this reason, many injection moulding companies are investing in increasingly complex production facilities. However, costly investments only pay when these facilities have a high rate of availability. A prerequisite for the permanent availability and reliability of an injection moulding machine is careful and efficient maintenance. Unscheduled stoppages and the resulting machine downtimes not only result in considerable costs, they also upset the entire production planning. Delivery delays, penalties for non-fulfilment of contracts and dissatisfied customers are the possible consequences. Occupational safety aspects are a further reason for regular maintenance. When resolving liability issues in the event of accidents, it can be crucial that safety-relevant maintenance work has been properly carried out. Wear is a natural, unavoidable process in the case of injection moulding machines. For instance, rubber materials such as hoses and seals age, even without direct use. The longest possible uptime is essential in ensuring economical production. The main purpose of preventive maintenance is to maximise the uptime by minimising wear. Through regular maintenance, wear can be controlled, necessary repairs can be detected in a timely manner and can consequently be planned. Possible faults, downtime and consequential damage can thus be prevented. The availability, reliability and therefore the efficiency of the injection moulding machine increases. Simultaneously, an excessive diminution in value of plant equipment is prevented. A further objective of preventive maintenance is ensuring safe working at the injection moulding machine. A significant benefit of prevention is the reliable planning of the maintenance and repair measures. Repairs can be carried out at the most favourable time. The basis for the inspection, lubrication and replacement intervals is the maintenance schedule contained in the operating instructions. Through careful documentation, the costs to be incurred can also be reliably allowed for. Important aid: Computer-assisted planning and documentation of maintenance and repair activities for machines and moulds can be performed using the ARBURG ALS host computer system. Moreover, ARBURG offers its customers the option of having all important machine elements inspected for wear, operability and safety on a regular basis by a service technician within the scope of an inspection contract. Our Service personnel will be pleased to answer any further queries: service_germany@arburg.com today 32/

18 Service Bremen Kiel Hamburg Rostock around the clock Neustadt Hannover Berlin Radevormwald Köln Worms Frankfurt am Main Stuttgart Lossburg Freiburg Erfurt Nürnberg Leipzig Dresden Rednitzhembach München ARBURG Service Allround - this is the extended range of ARBURG services available to the German market as of January It not only provides a hotline for telephone support around the clock, but in an emergency, service engineers can be requested even at weekends or on public holidays. Traditionally, a comprehensive and customer-orientated range of services has always been high on ARBURG s agenda and list of priorities. We constantly work to meet the challenges of the future head-on. The most recent result of this is the extended service range available to the German market, ARBURG Service Allround. It consists of a hotline which is available 24/7 and a callout service for service engineers at weekends and on public holidays. However, the new range of services required a structural change in the field of service. So that nothing was left to chance when implementing the service, it has undergone extensive testing at the service location Neustadt near Hanover since early Only after a successful trial run, were further Service Centres set up at the headquarters in Lossburg, at the ARBURG Technology Centre in Rednitzhembach, at the ARBURG Info Centre in Radevormwald and in Worms. Customers can reach their regional contacts at all five locations free of charge on weekdays between 7 AM and 5 PM for all service enquiries. In addition, an expanded paying hotline is available, which is operated by qualified ARBURG employees between 5 PM and 7 AM as well as around the clock at weekends and on public holidays. Their workstations are connected online to the ARBURG headquarters and the Service Centres so that they have access to all important customer information and machine data and equipment, and can provide comprehensive support. In urgent cases where it is indispensable that the fault be remedied at the weekend or on a public holiday, a service engineer can be requested using the expanded hotline. For these chargeable emergencies, a service engineer will be on standby duty in each service area and will come to your location between 8 AM and 2 PM. INFOBOX The Service Centres can be reached free of charge on weekdays between 7 AM and 5 PM: Lossburg: Neustadt: Radevormwald: Rednitzhembach: Worms: The chargeable hotline is available on workdays between 5 PM and 7 AM as well as 24 hours at weekends and on public holidays (except 24/25/26/31 December, 1 January and the Easter holidays) on today 25/2004

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20 Cycle time Efficiency Availability Choose efficient production: Increase product quality and reduce unit cost. How? By choosing maximum productivity with the fastest cycle times using energy-efficient, high uptime systems. The 100 % solution can only be found at ARBURG! ARBURG GmbH + Co KG Postfach Lossburg Tel.: +49 (0) Fax: +49 (0) contact@arburg.com