1、INJECTION MOLDING ENERGY CONSERVATION SEMINAR:MODERN INJECTION MOLDINGDavid O.Kazmer,P.E.,Ph.D.Northeast Utilities Auditorium,Berlin,CTEconomics 101=Energy Conservation 101?Adam Smith Wealth of Nations,1776 Each individual intending only his own gain must exchange what he owns or produces with other
2、s By division of labor and a free market,public interest is advanced.Does this“invisible hand”serve energy conservation?$0.25/serving$0.20/serving$0.35/serving$0.87/serving“Lets Play The Price Is Right”Economic choices are usually rational Role of government to provide transfer prices and incentives
3、Agenda Modern Molding Technologies Economic Structures&Data Evaluation of Injection Molding Class 0:Obsolete Class 1:Standard Class 2:Efficient Class 3:Lights Out Competitive Strategies ConclusionsMolding Technologies:Modular Molds Modularity&standardization have provided Reduced design time&mold to
4、oling costs 10 minute quick change in press Trend reversal Cheap molds Prototype molds Lower importance of quick change givenexcess capacityMolding Technologies:All Electric Machines All electric advantages 50%of the power Silent operation Cleanliness Precision Reduced AC costs Trend to continue Aut
5、omotive hybrids fuel motor technology Asian machine technology improvesMolding Technologies:Hot Runners Melt delivery systems provide:Low pressure drops Fast cycle times Zero material waste Tight quality control Trend to continue:Lower priced systems New technologies Economic decisionsMolding Techno
6、logies:Cavity Pressure Control Closed loop pressure feedback provides:Automatic V/P switchover Improved consistency Quality control data Trend to continue:Low cost sensors Cheap computers New technologies Improved control Improved sensingModern ManufacturingMolding Technologies:Automation Robotics p
7、rovides for:Reduced labor content(demolding°ating)Repeatable cycle times Fast cycle times Trend to continue:Cheap computers Low cost motors&standard designsMolding Technologies:Quality Control Quality control systems should enable:Automatic acceptance or rejection 100%part testing Automatic cycli
8、ng Variance analysis Trend to grow:SPC is crude Sensor:analysis explosion Improved capabilities Molding Technologies:Electronic Data Systems Electronic data systems should enable:Production scheduling Materials requirements planning Real time plant feedback Real time process feedback Trend to grow:N
9、etworked supply chains Science-based products Aggressive competitorsMolding Technologies:Others Coinjection Dynamic feed Gas assist In-mold assembly In-mold color In-mold film In-mold painting Insert molding Lost core molding Mold filling analysis MuCell Pad printing Pulsed heating Rapid prototyping
10、 Stack molds Thin wall Two-shot molding Water assistAgenda Modern Molding Technologies Economic Structures&Data Evaluation of Injection Molding Class 0:Obsolete Class 1:Standard Class 2:Efficient Class 3:Lights Out Competitive Strategies ConclusionsCost StructuresTotalProduction CostsTotalLabor Cost
11、sTotalConsumables CostTotalFacilities CostsMachineryMaintnceFacilitiesYield$/HrOutputDowntimeEnergyResinCost Parameters Cost parameters N.E.China Operator labor$13/hr$0.70/hr Eng/Mgt labor$30/hr$3/hr Energy cost$0.08/kWh ABS resin$1477/ton$950/ton Machinery cost$30/hr$15/hr Facilities cost$7.00/ft2$
12、4.20/ft2 Maintenance rate10%20%Agenda Modern Molding Technologies Economic Structures&Data Evaluation of Injection Molding Class 0:Obsolete Class 1:Standard Class 2:Efficient Class 3:Lights Out Competitive Strategies ConclusionsEvaluation of Injection Molding Case Study for a Mid-Sized Molder 200 mi
13、llion parts per year Average part weight:10gClass 0:ObsoleteOperating Conditions 8 cavities/mold with cold runners Poorly selected hydraulic machines(26 kW)50 seconds per cycle(optimistic)Cooling issues&semi-automatic 95%quality level(optimistic)1 operator per 1 machine 1 eng/mgt per 15 operators 2
14、shifts,5 days per week 4 hour setup per 10,000 partsClass 0:ObsoleteFactory Characteristics#Operators#Machines#Eng/MgtEnergy UseClass 0:ObsoleteCost DataClass 1:StandardOperating Conditions 16 cavities/mold with 50%hot runners Well selected hydraulic machines(30 kW)45 seconds per cycle(optimistic)98
15、%quality level(optimistic)1 operator per 2 machines 1 eng/mgt per 15 operators 2 shifts,5 days per week 2 hour setup per 10,000 partsClass 1:StandardFactory Characteristics#Operators#Machines#Eng/MgtEnergy UseClass 1:StandardCost DataClass 2:EfficientOperating Conditions 32 cavities/mold with hot ru
16、nners Electric machines(26 kW)40 seconds per cycle,fully automatic 99%quality level 1 operator per 4 machine 1 eng/mgt per 15 operators 3 shifts,5 days per week 1 hour setup per 10,000 partsClass 2:EfficientFactory Characteristics#Operators#Machines#Eng/MgtEnergy UseClass 2:EfficientCost DataClass 3
17、:Lights OutOperating Conditions 32 cavities/mold with hot runners Electric machines(22 kW)35 seconds per cycle Fully automatic including crating,etc.99.9%quality level 1 operator per all machines 1 eng/mgt per all machines 3 shifts,7 days per week 0.5 hour setup per 10,000 partsClass 3:Lights OutFac
18、tory Characteristics#Operators#Machines#Eng/MgtEnergy UseClass 3:Lights OutCost DataComparison New England China0246810121416180123Factory ClassTotal Production Cost($Millions)ShippingProductionHead to Head Competitive AssessmentValidation:World Production US Plastics industry went from surplus of$8
19、94 million in 2000 to a deficit of$1,387 million in 2002 A swing of$2,281 million.In 2001,China exported$6bn of fabricated plastic products last year.China also exports plastics in many other forms In 2002 China doubled the volume of its exports China is worlds largest petrochemical importer Chinese
20、 petrochemical demand is doubling every 8 years.Validation:Plastic Bags In 2003,US imported more than 100bn plastic bags A coalition(Intelplast Group,PCL Packaging and Sonoco Products)claimed that Asian countries were flooding the US market with below-cost PE bags and demanded an anti-dumping duty I
21、n September,the US Interl Trade Commission determined that there is a reasonable indication that a US industry is threatened with material injury by reason of imports of polyethylene retail carrier bags from China,Malaysia and Thailand that are allegedly sold in the United States at less than fair v
22、alue.A producer of plastic utensils found that they could purchase products from China for less than the cost of their resin.Agenda Modern Molding Technologies Economic Structures&Data Evaluation of Injection Molding Class 0:Obsolete Class 1:Standard Class 2:Efficient Class 3:Lights Out Competitive
23、Strategies ConclusionsCompetitive Strategies:Best Way Not to Compete Dont be an average custom molder Non-optimal,semi-auto cycles Low,variable production quantities High labor content Material cost disadvantages Higher volume jobs going overseas Lower volume jobs going to short run prototype shops
24、Middle volume jobs are scarce and cheapCompetitive Strategies:Product Specialization Research indicates plastic parts are 10-40%of product value Value is retained if vertically integrated Outsourced suppliers typically recoup 5-10%Processors should focus on products Vertical integration allows tight
25、 integration between market,design,and processing Product technology&IP raises barriers to competitionProduct Specialization Case Study Head up displaymaker Internal molder$15 reflector 0.25”Thick 100 sec cycle Very highretained profit Other example:Visteon&HVAC Units Other example:Nypro&cell phones
26、Competitive Strategies:Process Specialization Focus on advanced processes Technology allows new capabilities Investment,know how,and IP provides barriers for competition Process focus can lead to a market niche Market niche provides greater recognition with better,more confident serviceProcess Speci
27、alization Case Study Proto-mold Automated quote,design,build,mold$=f(Q,t)Suggested changes Parts in 5 days 100-10,000 qty$7.00-$3.00 vs.$0.40 in commodity market Other example:NAL&Stanley in auto lighting Use of multi-shot moldingAgenda Modern Molding Technologies Economic Structures&Data Evaluation
28、 of Injection Molding Class 0:Obsolete Class 1:Standard Class 2:Efficient Class 3:Lights Out Competitive Strategies ConclusionsConclusions Competitiveness isnt all about labor rates Automation&localization can largely offset True commodities(bags)in jeopardy?It is about efficiency Knowing which/how
29、to leverage technology and differentiation Market understanding,penetration,&recognition Product&process specialization Cost&time performanceFinal Thoughts Mid-Term Issue:Oil&Natural Gas Supply Increasing Asian demand Weakening dollar Government debt Trade deficit Euro as preferred currency Long-Term:Labor Demand Global supply of all labor Improving supply chains
