Production efficiency Think holistically reduce unit costs

Transcription

1 Production efficiency Think holistically reduce unit costs

2 Production planning Product design Mold technology Process control Production efficiency Machine technology Process integration Peripheral technology Configuration Production efficiency made visible: quantitative potential savings during injection molding provide for sustainable reductions in unit costs. ARBURG for efficient injection molding Production efficiency means making rational use of resources and exploiting the full available potential. This ensures maximum productivity at minimum operating costs, leading to a high level of efficiency for companies. We have been channeling all our efforts in this direction for decades. ARBURG aims to offer its customers perfect product quality at minimum unit cost. Our objective is to combine expertise and technology for maximum productivity with the shortest possible cycle times and maximum availability at the lowest possible energy requirement. We implement these principles on a daily basis in our own production. Added value: a holistic view If this objective of production efficiency is to be achieved, it is not sufficient to concentrate on energy efficiency or machine technology alone. Instead, the entire value chain and all variables should be included from product design to production planning. Each individual area offers the potential to reduce unit costs on a sustainable basis: by minimizing energy requirements, material input, personnel, processing time, production steps, downtimes and rejects. However, there are no patent recipes each company must find its own path for itself. Further information: Products and services brochure 2

3 Introduction Anchoring production efficiency in strategic terms The rational use of all resources is an ongoing task and therefore has to be pursued over the long term. Here, the choice and design of production equipment has a major influence on the subsequent efficiency of production. Thus, the planning phase for businesses is growing in importance. Any unforeseen issues at this stage can only be repaired to a limited extent in the production phase and usually only at considerable cost. However, if production efficiency is strategically anchored in the activities of an injection molding company from the outset, then such (additional) investments will pay off in a very short time. Making the most of ARBURG know-how In order to be able to produce cost-effectively and at competitive prices in the long term, manufacturing processes must be constantly reviewed and further developed. New processes and plastics, as well as the use of innovative machine and system technologies also play a significant role. However, in the final analysis, the best possible individual solutions call for interdisciplinary expertise. That is why we are also particularly broadly positioned: our expertise ranges from machine, robotic, control and process technology, through to computeraided production planning. Moreover, we have a strong network of partners, such as leading manufacturers of materials and molds. Tap into this unique pool of knowledge in order to implement efficient complete solutions from a single source. 3

4 Product design and material selection: significantly determine productivity and energy requirements Product design: optimize production from the outset Efficient molded part production starts with the product design. We can help you to continuously find new individual solutions. Together with you, we can fine-tune all the significant factors to ensure truly efficient production. Our approach is a holistic one: because we know what to look for in a design to enable important functions to be integrated in a part, thereby reducing production steps or enabling problem-free automation. Our applications technology consulting service allows us to offer you practical support quickly and reliably in all issues relating to molded part design and layout, as well as the choice of material. Reducing material input, shortening processing times The first way in which we increase production efficiency is through effective product design in terms of materials. This is because material savings lead to greater cost-effectiveness in a number of respects: the shorter cooling and cycle times achievable with thinner walls increase productivity and energy efficiency. Furthermore, designing the molded parts and their tolerances in line with the plastics used increases process reliability. Radiuses and angles ensure good demolding properties, for example. Intelligent material combinations mean that functions such as sealing by means of hard/soft combinations can be integrated directly in the part in order to reduce production steps. 4

5 Product design Production efficiency What you should do: Design products and define tolerances appropriately for plastics Save materials reduce wall thicknesses Combine materials in a targeted manner integrate functions in the component and minimize production steps Select plastics in a targeted manner optimize energy requirements Flow pattern simulation: clarify weaknesses in the product design before implementation. Targeted selection of materials By selecting the correct material jointly with us, you can set the course for efficient injection molding production from the outset. This is due to the different energy requirements for melting different plastics. Moreover, you often require temperature control or even heating during the processing of many technical plastics. This requires an additional expenditure of energy. Finally, production conditions, which may necessitate the use of interior air conditioning, for example, must also be taken into consideration. All of these factors have a sustained impact on your overall production process. The targeted balancing of product requirements and material properties is thus decisively important. Example: flow-enhanced plastics The plastic determines the effort required for material preparation and process temperatures. It should also be borne in mind that the higher the values, the greater the energy and cooling requirements and the longer the cycle times. Flow-enhanced plastics can contribute to significant savings in the injection molding process. Depending on component 280 Wall thickness of cont. spiral 2 mm, injection pressure 100 bar size and geometry, the lower processing temperatures and shorter cycle times result in greater energy efficiency, thus T approx. 40 K 220 reducing unit costs Flow path [cm] Processing temperature [ C] PA6 GF30 Ultramid B3WG6 High Speed Source: BASF SE 5

6 Near-contour, segmented temperature control: significantly high process control capability. Mold technology: reliably achieving quality In addition to product design and the choice of materials, molded part production is also significantly influenced by mold technology. Perfect quality and output can only be achieved if a precise approach has been taken for each detail when designing and implementing the mold. In the final analysis, this also means that mold and injection molding technology need to be coordinated in detail so as to work in perfect harmony. Thanks to its applications technology consulting and International Technical Service (ITS), ARBURG is perfectly placed to deal with such challenges on an international basis. Close cooperation with technology leaders in the field of mold construction leads to innovative solutions, however specialized your requirements may be. Targeted optimization with simulations Efficient production is characterized by consistent product quality in which mold technology plays a crucial role. Distortion of parts, sink marks, cold flow displacement, fiber orientation, or inadequate filling of the mold can be the reasons for unstable processes and unnecessarily prolonged cycle times. We can offer you detailed advice for targeted optimization on the basis of computer-aided simulations. Examples of effective measures to reduce cooling and cycle times are segmented mold temperature control, routing temperature control channels close to the cavity, and selecting the right temperature control medium. Generously sized media channels and short supply lines cut energy expenditure in and around the mold and the associated peripherals. 6

7 Mold technology Production efficiency Source: LBC What you should do: Design stable process e.g. reduce number of moving mold elements Use hot/cold runners sprueless injection molding Insulate heated molds reduce energy requirement Use near-contour cavity cooling enable fast cycles Select temperature control in a targeted way reduce cycle times, ensure Thermal mold design We also recommend taking a close look at temperature control in the mold. Frequently, neither the temperatures nor the quantities of cooling water are suitable for the relevant application, meaning that there is scope for further optimization here. If the feed temperatures of the cooling system can be increased without affecting the injection molding process, for example, considerable operating cost savings can be achieved for each degree in temperature. The improvement in water quality also ensures free pipe cross-sections and therefore lower energy costs and improved process control. Stable processes are also ensured by keeping the number of moving mold elements small, ensuring reliable demolding and separation of molded components from the sprue. Example: energy-saving insulation The insulation of hot mold parts against the environment and against neighboring machine components or cooling systems is a particularly effective measure for countering high energy losses. For example, hot runner systems should be insulated from the colder areas of the mold in 2 particular. The same applies to insulation of the mold towards the machine mounting platens, especially in the case of 1 temperature-controlled molds. Energy requirement [kwh] 0 without insulating panel Supplied energy with insulating panel Energy savings 7

8 Drive technology: define the precise range of functions and performance of an injection molding machine. Machine technology: reduce cycle times in a targeted manner The associated running costs and performance should always be taken into consideration when deciding for or against a particular machine concept. It is hard to believe over a machine s entire life cycle, potential savings significantly outweigh pure investment costs. You can take our word on this after all, machine technology has been our area of expertise for over 50 years. During this time, we have developed a comprehensive, fully modular product range from which you can select your machine and drive technology on an individual basis. We have the right solution for each of your injection molding tasks. To ensure that you remain satisfied with our ARBURG products and therefore with your own production for years to come, we also maintain our standards to the highest level. This is guaranteed by our seal of quality - Made by ARBURG - Made in Germany. Focusing on performance Drive technology has a major influence on energy efficiency and cycle time. Electric drives score highly here with their energysaving, fast and simultaneous movements, as well as braking energy recovery. In the case of hydraulic systems, short cycle times can be achieved by means of multi-pump or hydraulic accumulator technology, for example. Energy requirements are reduced through the use of IE3 motors or efficiencyoptimized hydraulic drives in which the rotational speed of the pump drive is adapted to the different requirements of the injection molding cycle. However, in terms of drive technology, it should be emphasized that an electric injection molding machine may not always represent the most costeffective solution. A detailed analysis of the relevant application and its production parameters will benefit you here. 8

9 Machine technology Production efficiency What you should do: Implement fast, simultaneous processes, e.g. multi-pump/hydraulic accumulator technology or servo motors Utilize energy-saving potential for example, use IE3 motors or speedregulated pump drives Cool drives using water and insulate cylinder modules reduce waste heat Comparing cost-effectiveness Efficient solutions are achieved by individually combining the various drive concepts. The modular ARBURG product range offers a high degree of flexibility. In order to determine the best solution for the application at hand, we use a machine comparison and cost-effectiveness calculator, which takes all the key parameters into account in order to calculate the unit costs. This tool very clearly illustrates the respective influences of factors such as productivity and energy requirements, as well as indicating the amortization periods for more expensive machines. With these analyses, it has been revealed time and again that shortening cycle times has the greatest impact on reducing unit costs and therefore on the cost-effectiveness of molded part production. Example: synchronous ejection Fast cycles are enabled to a significant extent through fast, reliable ejection. We can also offer you practical solutions with regard to this important detail. The combination of servo-electric toggle-type clamping unit and servo-electric ejector is highly effective and results in short opening and closing times thanks to the precise, reproducible dropping of molded parts. ALLROUNDERs Clamping unit Ejection Core pull Nozzle movement Ejection Dosage Electric Hybrid Hydraulic Electric Hydraulic 9

10 Central material supply: smooth production with a high degree of autonomy Peripheral technology: systematic selection of equipment Production efficiency is only achieved when all areas complement each other in terms of their effect and produce a successful whole. It is consequently not always sufficient to find the right mold and machine technology if the right environment has not also been selected. Because we are aware of this, we offer you not only our modular ALLROUNDER injection molding machines, but also precisely coordinated peripheral technology that can be operated via the SELOGICA control system. The keywords here are six-axis robotic system powered by ARBURG, MULTILIFT robotic systems and THERMOLIFT material driers and conveyors. We also cover all remaining requirements by closely cooperating with leading manufacturers of automation and peripheral equipment. This is why ARBURG is a system supplier, as it is only in this way that it can provide companies with the best possible injection molding technology! Ensuring ease of operation Speed-controlled electric drives are preferable to pneumatic systems for peripheral components such as robotic systems or systems for preparing and conveying materials. These systems offer you advantages not just in terms of cycle time reduction, but also with respect to precision, energy efficiency and operating comfort. Central control and monitoring of all the peripherals by the machine control system is a further convenience. The complete integration of the systems in a central process management process saves time during the programming, operation and monitoring of the entire technology, which has a positive effect on the cost-efficiency of production as a whole and thus also impacts on unit costs. 10

11 Peripheral technology Production efficiency What you should do: Use speed-controlled, electric drives instead of pneumatic systems Keep hoses short, insulate if necessary Use partial climate control Actuate and monitor peripherals centrally Flexible perfection in motion: thanks to the implemented SELOGICA user interface, six-axis robotic systems can even be programmed by machine installation technicians. Holistic view of the environment The use of water-cooled modules, such as assemblies and motors, reduces both heat output and the associated pollution of the environment. At the same time, the dissipated heat is exploited for the purpose of energy recovery. Depending on the prevailing production environment, this can be of major importance, e.g. when producing molded parts under clean room conditions. Our carefully tailored accessories, such as rapid mold clamping systems, automatic feeders, or unscrewing units help you to always produce to the highest quality. This is because all our products fit together to perfection. Example: fast sprue removal In comparison with a pneumatic picker solution, the servo-electric movement axes of the INTEGRALPICKER V require no further set-up when changing orders. The servo motors also enable significant cycle time reductions of more than one second. The Y entry axis, for example, is exceptionally dynamic and reaches speeds of up to 2 m/s, combined with a high X level of repeat accuracy. Furthermore, any number of axis positions can be programmed, such as an intermediate stop (waiting position) above the mold, for example. B 11

12 ARBURG s expert database: the right injection molding technology for every application. Configuration: flexibly combining components The optimal system technology always depends on the application. Jointly with you, we can configure and fine-tune machine concepts for your specific process. You should however take this approach from the very outset when planning the purchase of a system, in order to consider all production efficiency aspects in a targeted manner. This is the only way to ensure that your injection molding technology operates just as you intend. By working with us, you will benefit from a consulting service that makes it significantly easier for you to choose the right product. Individually adapting technology If you really want to use injection molding technology as efficiently as possible, it is important to choose the right individual components and the appropriate dimensions in relation to cycle times and energy efficiency. In order to ensure the greatest possible flexibility when adapting the machine sizes and injection processes, ARBURG offers a wide range of modular equipment and expansion levels. The extensive range of options for combining clamping units (clamping forces and distances between tie bars) and injection units (shot weight and material throughput), plus the appropriate drive technology, is of particular interest. This also means that a combination that functions perfectly in terms of energy and the technical process can be created for every requirement. 12

13 Configuration Production efficiency What you should do: Adapt the machine and peripheral performance precisely to the product and process Select and dimension the individual components in an adapted manner Exploit the broad product selection The most cost-effective solution at a glance: for smooth high-volume production, ARBURG as a technology partner provides detailed advice on the right technical equipment. ARBURG applications technology: all-round consulting Our Applications Technology department will ensure that your machines have the right design. In this department, we pool our entire expertise in applications technology to provide professional advice that caters to every possible requirement. We can offer you not only a detailed concept for processing technology with a number of alternatives, but also if required a thermal process balance sheet or energy analysis. This is based on our intelligent, learning application database, which brings together a huge range of internal tests, enabling conclusive information be derived. Our Customer Center has its own laboratory and also provides the perfect environment for in-depth testing and trials. Example: energy-efficient plasticizing The right choice of injection unit size and screw diameter has a significant influence not only on part quality, but also on energy requirements. The higher the utilization of an injection unit, the lower the specific energy requirement. High utilization of the injection unit is in turn promoted by short cycle times. In contrast, the difference in energy requirement between 7 the various drive remains practically con- 6 stant across the entire 5 operating range. 4 Specific energy requirement [kwh/kg] Material throughput [kg/h] Hydraulic two-circuit pump technology Energy-optimized hydraulic two-circuit pump technology Direct electric drive 13

14 Optimize material flow and logistics: automation systems link injection molding with other processes and allow ready-to-install parts to be produced at a single location. Process integration: extensive reduction in operating steps Work is becoming an increasingly important aspect when analyzing the factors that influence unit costs in high-wage countries. Costs can be saved by integrating processes in a rational way under production efficiency aspects. We can offer you the full range of our expertise in your search for the most cost-efficient production solution. Since 1996, ARBURG has been running a separate project department that deals with the integration of upstream and downstream processing steps in all-embracing automation solutions. Working in collaboration with Application Engineering, Machine, Robotic and Control Technology, the specialists in this group have developed solution concepts encompassing all known injection molding processes. In this sector too, you can benefit from the strong network of our partners, gaining an advantage from specialists in six-axis robotic systems, material flow or logistics. Your advantage: you receive full system technology, know-how, consulting and service from a single source. Automation and inline processes rational integration The efficiency of molded part production can be increased sustainably by incorporating upstream and downstream steps in the production process, e.g. using assembly injection molding or by encapsulating one or more inserts. This reduces manual work, optimizes logistics and, in the final analysis, increases productivity through time and cost advantages. Integration begins with the automatic provision of insets and ranges from fast, reliable part removal to inline quality assurance, inline printing, further processing and sales-ready packaging. 14

15 Process integration Production efficiency What you should do: Integrate upstream and downstream process steps Automate provision of inserts Ensure process-reliable, fast part removal Perform inline quality assurance and packaging Optimize logistics and material flow Customized: full support for tailored production solutions. Turnkey projects Projects or production cells are individual, customized solutions, which cover various requirements in terms of the combination of ALLROUNDER injection molding machine, robotic system and peripherals. As a general contractor with overall responsibility, we can offer you individual customer support for the complete planning process, as well as on-site installation and commissioning through to all the necessary services. This results in automated production cells precisely adapted for maximum production efficiency. Example: foaming in the injection molding cycle In the case of the so-called Mold n Seal process, an injection molding machine is linked to the mixing and dosage unit via a six-axis robotic system for the foaming process. The sealing material is applied to the plastic parts while they are still warm, directly after the injection molding process. The use of the resulting residual heat from the molded part further speeds up the foaming and cross-linking reaction process. This fully automatic inline foaming saves a great deal of time and money. Film 15

16 Credit-card format: selective access authorization for control data. Process control: working to a consistently high quality standard We can offer you very specific support with process control, helping to optimize your production processes. We are just the right partner for you in this context: After all, in addition to our machine technology, our core areas of expertise also include process control, where we possess excellent knowhow. Why is process control so important for production efficiency? Because this is where the potential exists to make daily savings in your production process on an independent basis at no extra cost. The important options for reducing energy and cycle times and for a consistently high level of quality, securing your economic advantage over your competitors. We can help you do it! Maintaining a stable production process Our SELOGICA system is designed for universal use in the programming and control of all known injection molding processes. This is a control system made by injection molders for injection molders; as an inhouse development, it is practical and can be adapted to customer-specific requirements as well as being ideally suited for integration in your entire range of peripherals. Maintain a stable production process and comply with all the necessary quality requirements, so that malfunctions and rejects are minimized, while ensuring a continuously high level of productivity. Synchronize the movements of ALLROUNDERs and peripherals, optimize processes and monitor quality comprehensively all from a central control system. Implement automated production starts using individual start-up programs. 16

17 Process control Production efficiency What you should do: Ensure smooth production, minimal waste and optimized processes operate productively Monitor quality continuously thanks to a central control system Automatically start production in a fast and controlled manner Synchronize movements reduce cycle times A proactive approach: qualified employees think and act efficiently. Individual adaptation of settings Our SELOGICA control system can be used to implement complex processes simply and reliably. Even the best machine only works as well as its settings permit. This is true for the quality of the molded parts, the cycle time and energy requirements. Thus, you can save energy if you do not operate your ALLROUNDER at maximum temperature, but rather at the melt temperature appropriate to the article in question or if you exploit the full cooling time for plasticization. Example: synchronization of sequences An example will show how synchronizing sequences can help optimize a process: A robotic sequence usually operates on a serial basis via Euromap. SELOGICA can also be used to synchronize the ejector and X-axis, and to start the Y-axis as the mold is opening. This potential for optimization is also supplemented by the option of moving the ejector to an intermediate position. This makes your production process much faster and therefore more economical, something worth its weight in gold in high-volume production. Website 17

18 Production at a centralized glance: perfect machine capacity utilization. Production planning: optimum utilization of resources The formula for success in global competition is to produce flexibly, fast, to a high standard and at low cost. Reliable and therefore efficient production planning is becoming increasingly significant. All existing potential areas for rationalization require a far more holistic approach than merely an examination of system technology. It is only possible to save costs in the long term by making use of synergies through more rational production overall. ARBURG can also offer you the right technology for achieving greater production efficiency in this area. We have had our own host computer system since 1986, making the entire production planning process much easier. We continue to develop this system in close association with our SELOGICA control technology, creating a planning tool designed by injection molders for injection molders that you can rely on in every possible situation. Rational organization of production For efficient molded part production, time is always an important factor not just in terms of cycle times of the applications. The primary concern is to minimize the non-productive phases when machines are idle, bringing no material benefits but still requiring energy in many cases. Among the measures to remedy this are the optimization of work processes in production, such as during set-up, as well as proactive production planning. Other aspects include preventive maintenance and quality assurance. This enables you to avoid malfunctions and the associated unplanned machine stoppages. On the other hand, you can minimize the reject rate of your production system and therefore save not only time and energy, but also material costs. 18

19 Production planning Production efficiency What you should do: Avoid downtimes perform preventive maintenance Plan production proactively Optimize batch running times Combine interruptions Minimize downtimes and set-up times Utilize unmanned preparation Design ergonomic work stations Immediate reliable information: production data available online at all times. Central management of production The ARBURG host computer system (ALS) helps to cut downtimes and set-up times, or reduce the reject rate, thus improving the use of all available resources. Detailed planning on the basis of reliable data helps you to reduce the number of heating and start-up phases by optimizing batch sizes and by merging the times for maintenance and service activities. However, ALS not only supplies you with all the key data for comprehensive production and resource management, it also enables you to provide setting data on a centralized basis, to demonstrate process quality and to document and archive production processes in a reliable way. Example: faster set-up times Perfect preparation is of crucial importance for a fast changeover. Checklists help to ensure that nothing gets forgotten. In addition, a well-organized cart with all the required molds, bolts, and even hoses should be available prior to every set-up. This means that everything is in place as soon as the machine stops. Nothing needs to be searched for or fetched. After all, as the graphic shows, every unnecessary journey represents a potential waste of time. Quality assurance 4 x 4 m Material box Maintenance 4 x 40 m Fetch hose Mold 4 x 10 m 4 x 40 m 4 x 3 m 18 x 6 m 6 x 3m 14 x 2 m 9 x 4 m Mold trolley 5 x 7 m Total: 701 m 6 x 2 m 5 x 14 m 4 x 5 m Machine cabinet Source: Fischer Consulting 19

20 Achieving long-term success: efficient production thanks to a holistic approach. Success: gaining competitive advantage through production efficiency We take a two-pronged approach to production efficiency. Our declared goal is to continually increase efficiency and cost-effectiveness not just in our own company, but also for all our customers in such a way as to give them a permanent edge over the competition. Our support goes far beyond machine technology. For example, our holistic approach shows ways in which entire production areas can be designed and realized to optimum effect in order to reduce unit costs. This perspective ties in with ARBURG s general approach as a system provider: we offer you excellent support throughout the entire value chain. This is also reflected in our company maxim, ARBURG for efficient injection molding. We want you to be successful together with us and through us! Perfect custom solutions Owing to the many influencing factors, working in a truly efficient manner is a genuinely challenging task. The key principle is always high product quality at the lowest possible unit costs. Our coordinated product range, together with our comprehensive consulting service, enables us to offer our customers the best possible individual solutions for efficient molded part production. Your advantage: each of your ALLROUNDER machines is unique, even though their modularity means we can offer them at series prices. In addition, as a further unique selling point, we can offer our unique mix of know-how, ranging from machine, robotic and control technology, applications technology, implementation of turnkey projects and software, through to production planning. 20

21 Summary Well-founded expertise: practical first-hand knowledge of all questions relating to injection molding technology. Getting employees and infrastructure into shape In addition to all the technology, people are always a decisive success factor. As a result of the constantly increasing requirements facing injection molders, it is extremely important that the qualification of employees is furthered through ongoing training and that awareness of energy efficiency is raised. In addition, the extended production environment should also be included in your efficiency efforts for example infrastructure or facility management. This makes it possible to determine possible additional potential savings that will make your production even more effective and cost-efficient. ARBURG also plays a pioneering role in this area, enabling its customers to benefit from its experience. Expertise: injection molding consulting from ARBURG ARBURG provides its customers with comprehensive advice on every possible question relating to injection molding technology. This service also includes detailed injection molding consulting. We employ a precise planning aid here: For detailed production hall layout For energy and cooling water supply For the complete material flow For energy and production efficiency An individual and holistic approach of this kind is the only way to further increase the cost efficiency of your production. We therefore boast a far-reaching network of internal specialists and strategic partners for providing our customers with optimum support and advice. Together we are always working on the best solution specially for you. 21

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23 Production efficiency counts! A broad perspective is essential: every day, some 3.5 billion high-quality plastic parts are produced on ALLROUNDER machines so the utmost production efficiency is required. If you are seeking to produce that efficiently, we are the right choice. We ensure your economic success. ARBURG for efficient injection molding. 23

24 ARBURG for efficient injection molding. We implement this approach in our own production on a daily basis. ARBURG GmbH + Co KG Arthur-Hehl-Strasse Lossburg Tel.: contact@arburg.com With locations in Europe: Germany, Belgium, Denmark, France, United Kingdom, Italy, Netherlands, Austria, Poland, Switzerland, Slovakia, Spain, Czech Republic, Turkey, Hungary Asia: People s Republic of China, Indonesia, Malaysia, Singapore, Taiwan, Thailand, United Arab Emirates America: Brazil, Mexico, USA For more information, please go to ARBURG GmbH + Co KG The brochure is protected by copyright. Any utilization, which is not expressly permitted under copyright legislation, requires the previous approval of ARBURG. ARBURG GmbH + Co KG DIN EN ISO certified _EN_US_ Subject to alterations Printed in Germany