complex insert molding applications - automate complex insert molding applications •identifying...
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Complex Insert Molding Applications
Dino A. Caparco
Engineering Operations Manager
Yushin America, Inc.
Complex Insert Molding Applications
• Identifying Opportunities and Evaluating Return
• Tooling Design Considerations
• Value Added Operations
• Examples of Complex Tooling
• Successful Implementation
Identifying Opportunities and Evaluating Return
• Labor Savings• Reduced operator utilization• Reduced mold open time• Semi-automatic vs. fully automatic
• Quality Consistent cycle time• Part placement for cooling• Inspection of inserts going into equipment• Proper loading and verification
• Safety • Remove operator from hazard• Ergonomics
• Internal Competencies• Current automation level• What level can you support now• Troubleshooting capabilities
Identifying Opportunities and Evaluating Return
Tooling Design Considerations
• Review with toolmaker and automation company• Design mold to be “automation friendly”
• Insert locating features
• Robot docking features
• Tooling materials• Weight constraints
• Medical or cleanroom requirements
• Material treatments
• End-of-Arm Tooling electrical requirements• Component sensors
• Communications
• Insert design• Tolerances
• Finish
• Dirt or debris
• Leads or broken edges
Value Added Operations
• In-mold inspection and verification• Avoid tool damage
• Post mold inspection • Quality control
• Inserting mold cores• Threading applications
• Electrical terminal applications
• Automatic tool change
• In-Mold labeling
• Insert Placement and
verification
• Locating Cylinders
• Docking Modules
In-Mold Labeling
• Environment impacts
functionality
• Material flow
• Label flatness
• Re-orientation of parts
• Post mold
measurement
• Individual part reject
• Insert cores with
terminals
• Post mold
continuity test
• Carbon fiber plates
for weight
reduction
• Lock and dock
• Insert Placement on
both mold halves
• Grippers to lock and
dock
• Very large product
• 21 Inserts total
• Operator loads end-of-
arm tooling direct
• Docking Modules
• Two robots working on
one part assembly
• Shuttle station to
orient parts for loading
into second mold
Semi-Automatic System
Successful Implementation
• Vendor should generate an installation plan• Identify pre-install requirements• Install support requirements
• Final Run-off • Cycle time• Uptime
• Training• Automation start-up• Recoveries• Level of authorization for operators vs. technicians
Successful Implementation
• Ensure the right people are trained on the equipment
• Become the expert on the equipment
• Work instructions for operators
• Stock spare parts for consumable items
• Error data and uptime tracking
• Systematic process for troubleshooting• Limit access to make changes• Methodical, step by step• Get to the root cause
Yushin America, Inc. – Contact Information
Dino A. CaparcoEngineering Operations Manager
Yushin America, Inc.35 Kenney Drive
Cranston, Rhode Island, 02920
USA
Telephone: (401) 490-4955
Email: [email protected]
www.YushinAmerica.com