TIM: Total Integrated Manufacturing

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1 TIM: Total Integrated Manufacturing Makes in-mold assembly more flexible Allows fast product changes Increases cost-effectiveness Mold Making

2 Z.TIM: The new freedom for in-mold assembly Makes in-mold assembly more flexible Allows fast product changes Increases cost-effectiveness Total Integrated Manufacturing (TIM) with Z.TIM or Z.TIM light opens up a whole new freedom for in-mold assembly. The separation of mold frame and cavity part, plus relocation of the assembly plates to freely moving external units makes the production of assembled plastic modules much more flexible. This, in turn, makes for more efficient and cost-effective in-mold assembly the intelligent solution. TIM solution 1: Z.Tim Maximum flexibility at turbo speed Z.TIM is the cube tool for Total Integrated Manufacturing. With rotating assembly plates that have almost total freedom of movement, this intelligent tool offers maximum flexibility for in-mold assembly. IM makes in-mold assembly more flexible without increasing cycle time. relocating the assembly operation to external moving plates creates whole new possibilities for in-mold assembly with Z.TIM and Z.TIM light. Different assembly operations (or other processes) are possible, regardless of the tool sequence. Injection and assembly processes take place concurrently so that cycle times are not extended. TIM solution 2: Z.Tim light Total Integrated Manufacturing on standard machines Although Z.TIM light, the cube tool's little brother, is not quite as fast as Z.TIM, it does provide in-mold assembly using the TIM principle on standard machines. IM allows fast product changes The mold frame and cavity part are separate, so the two TIM tool systems can be converted to new product designs or successor products with comparatively low investment (by replacing the cavity inserts). Changing the gating point, assembly direction or position are no longer an issue with TIM. This becomes increasingly more significant as product life cycles become ever shorter. This push-pull closure is a typical TIM application with all three individual parts being assembled in one tool. Furthermore, the complete closure is assembled without extending molding cycle times. TIM is also ideal for molding, assembling and testing parts for medical technology. IM increases cost-effectiveness Modularity is also a plus point in terms of cost-effectiveness. This is because the more flexible setup allows the two TIM tool systems to be written off over a longer period, and the investment costs for subsequent products are vastly reduced.

3 Solution 1: Z.TIM most flexible and efficient The Z.TIM working principle using the example of a three-part assembly Assembly unit 2 Injection unit 2 Injection unit 1 (4-way tool) Z.TIM has two cavity sides and two assembly sides, allowing the injection molding and assembly to take place concurrently. This is how it works: = 1 Assembly unit 1 (folded out) Turn-stack Z.TIM is a new innovative type of cube mold. It consists of a central turn-stack in the middle with two assembly units at its sides. The assembly units (orange) are positioned opposite one another and are docked onto the tool externally. This allows assembly operations to be carried out independently of the injection molding process. The assembly units are very flexible; they can be move in different planes and/or perform different processes, including: 1. Injection and Cube Rotation Three parts are molded (Red, Green and Blue) in the initial phase of the assembly process. Z.TIM then rotates the cube 90º to move the Red and Green parts into position for transferring to the external assembly mechanism Final Assembly of Third Part The assembly mechanism moves into position and assembles the Red parts to the Green and Blue part Sub-assemblies still on the idle side of the Cube and finally ejects the finished 3pc assembly Injection & Parallel Part Removal The assembly mechanism picks the Red and Green parts from the idle sides of the Cube while new parts are injection-molded on both cavity sides of the cube. 1. Moving on XYZ axis for basic assembly; º rotation for assembly, testing and ejection; 3. Auto-feed and assembly of external parts to the molded assemblies with optional final testing and ejection The benefits of Z.TIM at a glance: E fficient in-mold assembly during primary machine time 9 5% operational efficiency of molding and assembly processes S hortest possible cycle times R educed scrap and work-in-process inventories wo or more parts can be assembled on one mold 4 Z.TIM s mold tooling (green) is a modular designed construction including cavity inserts that can be exchanged at any time; this allows for other products to be made on the system regardless of product shape or gate point. This significantly reduces the investment needed for future products. 3 A vailable for injection molding machines up to 600t - for larger production volumes esting and other processes can be integrated into the production sequence F uture-proof as system can be flexibly converted for new products with interchangeable cavity inserts and assembly tooling C an be retooled at a much lower cost than that of the original investment 4. Assembly of First two Parts The flexible assembly mechanism assembles the green parts (previously picked and held) to the Blue Parts on the idle side of the Cube. 3. Rotation & Preparation for Assembly Z.TIM rotates back to the home position thereby presenting the Blue parts to the assembly station.

4 Solution 2: Z.TIM light TIM on standard machines The Z.TIM light working principle using the example of a two-part assembly Z.TIM light allows multiple parts to be injection molded and assembled during primary machine time. = 1 1. Opening of the tool preparation for removal Two types of molding (yellow and blue) have been injectionmolded with Z.TIM light. When the tool opens, the moving assembly plates move in to pick up the parts. 3 Z.TIM light is the little brother of the Z.TIM cube tool. The light version also has the assembly units positioned outside of the injection mold (Yellow). When the mold opens, the assembly units move in to remove the molded articles. Once out of the mold, parts are assembled in parallel to the injection process, as with Z.TIM. The assembly plates are extremely flexible, can move freely and be assigned different functions, e.g. assemble, populate, test or eject. Depending on the configuration, Z.TIM light can also assemble more than two parts. 2 The benefits of Z.TIM at a glance: E fficient in-mold assembly of during primary machine time 9 5% operational efficiency of molding and assembly pro- cesses R educed scrap and work in process inventories Lower investment cost wo or more parts can be assembled on one mold A vailable for Standard injection molding machines esting and other processes can be integrated into the production sequence F uture-proof as can be flexibly converted to new products (i.e. cavities and assembly tooling) C an be retooled at a much lower cost than that of the original investment The cavity inserts in the molding parts of Z.TIM light (green) can be replaced at any time. In this way you can set up for new products or changes to existing products.only the cavity inserts have to be changed, which means that investment in new products is once again significantly lower. 3. Assembly (parallel) injection As Z.TIM light closes again and new parts are produced, the removed moldings are assembled to form a module - during primary machine time and without extending the cycle time. 2. Removal of the moldings The assembly units transport the removed moldings to the assembly level. This example illustrates how it works with reference to a two-part object. Z.TIM light can inject and assemble more than two parts, however, depending on the configuration.

5 The Major Benefits of the TIM Tool Systems at a Glance: Unique flexibility in the in-mold assembly of multiple parts with high process reliability and output. Only the cavities have to be changed for subsequent products - regardless of shape, gating point or direction of assembly. A future-proof investment that pays for itself faster when products change and can be written off over a long period. Comparison of TIM tools Z.TIM in-mold assembly using the TIM principle with an intelligent modular cube tool Perfect for manufacturing closures, other packaging elements and technical medical parts Maximum flexibility at very high speed Modular structure allows fast product changes special machine with turn-stack required Z.TIM light In-mold assembly using the TIM principle with intelligent modular tool Perfect for manufacturing closures, other packaging elements and technical medical parts great flexibility and competitive pricing at slightly slower speeds Modular structure allows fast product changes Can be achieved on standard machines Intelligence in Form When plastic has to be formed into unique functional shapes, traditional custom injection molds are sometimes not sufficient. Intelligent solutions present new technical possibilities for injection molding, process control and optimization of production efficiencies. Whether for medical, packaging or personal care industries the development and implementation of intelligent solutions for the optimized production of plastic products demonstrates the strength of Zahoransky Formenbau. True to the principles of the group to which we belong: Zahoransky Leading edge technology in plastics engineering ZAHORANSKY Formenbau GmbH Bebelstraße 11 a D Freiburg Tel moulds@zahoransky.com Freiburg Rothenkirchen India