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2

2.1
(2539 : 55)

2.1.1 (Fixed half and moving half)


2

2.1
: (2539 : 56)

4
2.1.2 (Impression)


2
1. (Cavity)
2. (Core)
2.1.3 (Cavity and core plates)

2


2.2
: (2539 : 56)
2.1.4 (Mold cavities and core)
1.

2.3
: (2539 : 58)
2. (Inserts : cavity and core)







2.4
( )
( )
( )
( )
: (2539 : 61)
2.1.5 (Bolsters)


1.
2.
3.

7


5
1.
2.5

2.5
: (2539 : 67)
2. 2.6 ()
3.
2.6 () ()
4. 2.6 () ()
5.
2.6 ()

2.6
: (2539 : 67)
2.1.6 (Guide pillars and bushes)



2.7

2.7
: (2539 : 72)

9
2.1.7 (Sprue bush)


2.8

2.8
: (2539 : 78)

2.9 () ()
: (2539 : 78)

10
2.1.8 (Register ring)


2.10
: (2539 : 80)

11
2.1.9 (Runner and gate systems)

2.11

2.11
: (2539 : 82)
2.1.10 (Attachment of mold to platen)
2

1.

2.12

2.12
: (2539 : 83)

12
2.

3 2.13

x 2.13

2.13
: (2539 : 84)
2.2
(2542 : 78) (British
standard) B.S. 381 (Maintenance)



13
2.2.1 (Planned maintenance)

2
1. (Preventive maintenance)


2. (Corrective maintenance)

2



2.2.2 (Unplanned maintenance)








2.14

14
(Maintenance)

(Planned maintenance)

(Preventive maintenance)

(Running maintenance)

(Corrective maintenance)

(Shut down maintenance)

(Unplanned maintenance)

(Emergency maintenance)

(Breakdown maintenance)

2.14
: (2547 : 50)
2.3
(2547 : 20)





15






Breakdown





2.3.1
5


2.3.2



2.3.3





16


1.


2.

2.3.4


2.3.5


2.3.6

1. (Maximum availability)
Breakdown
2.

3.

4.
5.

17
2.4
(2551 : 4-6)





2.4.1 ECRS

1. E-Eliminate
1)

2)
3)

2. C-Combion
1)

2)

3. R-Rearrange
1)
2)
3)
4. S-Simplify
1)
2)
3)

18
2.4.2

5W 1H
ECRS
2.1
2.1

(Why)

(Eliminate)

(Why)

(Why)

4.

5.

(Why)

(Why)

1.
(What)

2.

(Where)

3.

(When)

(Who)

(How)

5 W 1H

(Combine)

(Rearrange)

(Simplification)

ECRS

: (2551 : 4-7)
2.5 (Fish - Bone )
(2550 : 277)

2.5.1
()

19

4 (Man)
(Machine) (Method) (Material)

2.15

2.15
: (2550 : 277)
2.5.2
1.
2.
3. 4M (
)
4.
5.

20
2.5.3
1.

2.

3.
2.6 (Check Sheet)
(2550 : 278)

2.6.1



2.6.2

1.





2.

3.

4.
2.16

21

: ..
:
: ,,
,
1,525

: ..
:
: ..
: .
:


//// //// //// //
17
//// //// /
11
//// //// //// //// //// /
26
///
3
////
5

62

2.16
: (2548 : 147)
2.6.3
1.
2. ( )
()
()
3. ( )

(What-) (Location)
(Where) (Timing)
(When) (Who) (How)
(Why)
5W 1H

22
2.6.4







2.7
(2547 : 55)




2.7.1
1.
2.
3.
Operator
Routine maintenance
1)


2)
Checking Inspection & Checking
3)

23
4)
5) Set
6)
7)
2.7.2 3
1. Minor (Current) Repair

1)

2)

3)
4)
(Load)
5)
Production line

2. Medium repair Minor repair
Schedule

1)
2)
3)
4)
5) Check
6)
7) Down time
3. Major overhaul

24
1)



2) Assembling

3) Testing Assembling

25
2.17

Preventive maintenance
flow chart

Machine name list

()
()

2.17
: (2547 : 56)

26
2.8
(2542 : 89)
2.18

2.18
: (2542 : 89)
2.9
(2547 : 75)

2.9.1 MTBF (Failure)


2.1

2.1
MTBF =

27
2.9.2 MTTR (Repair)
(Availability) 2.2

2.2

2.9.3 (Availability : A)
(Down time)

2.3
MTTR

A =


100

2.3

2.9.4 (Performance efficiency : PE)


2.4
)
PE (
=

100

2.4

2.9.5 (Quality rate : QR) Yield



(Good output) (Processed amount)
2.5
QR

( )

100

2.5

2.9.6 OEE
(Capital asset)

2.6
OEE = () 100 2.6

28
2.10
(2546 : 204)

2.10.1

4M1E (Man) (Machine) (Material) (Method)
(Environment)

2.10.2
2
1. (Product standard)


(ATM)

2. (System standard)
(4M1E)
ISO 9000
ISO 14000

2
1) (Technical standard)
( )

2) (Process standard)

29
2.10.3

1.

2.

3.

4.

5.


6.



2
1)


2)


30
2.1)

2.2)

2.3)

2.4)

2.5)

2.11
(2539 : 132)



2.11.1
1.
2.

3.
4.
2.11.2 Sprue Sprue Sprue Undercut
1.
2.

31
3.
4.
2.11.3 Sprue
1. Sprue
2.
2.11.4 (a)
1. Sprue Runner Undercut

2. (Taper)

2.11.5 (b)
1. Undercut
2.

3.
4.
2.11.6
1. Runner Runner
2.
3. Gate
4.
5.
6.
2.11.7 (Flash)
1.

2.
3.
4.

32
2.11.8
1. Gate
2.
3.
2.11.9
1. Gate Gate
2.
3.
2.11.10 (Sink mark)
1. Runner Gate
2. Runner

3.
2.11.11 (Weld line)
1. Gate
2. Gate
3. Gate Gate
4.
5.
2.11.12 (Scaling)
1.
Runner Gate
2.11.13 Gate
1. Runner Gate
(Cold slug well)
2.11.14
1.
2. Runner Gate
3.
4.

33
2.11.15
1. Runner Gate
2. (Cold slug well)
2.11.16
1.
2.12
(2539 : 14-5)

2.2
2.2


(Hopper)


sprue

34
2.2 ()

Runner
Runner

35
2.2 ()

mm2

1
mm2

(
)
(
Gate
)
(
)

()

PC
PC

160 ~ 180 OC

36
2.2 ()

Hot-runner


Hot-runner


Hotrunner

Delamination Sprue

(
)


Gate

Gate
Sprue

Gate
( Runner


)
-

37
2.2 ()

PC)
( ABS)

Cold slug



Sprue bush
Sprue bush

Gate

Runner Gate

38
2.2 ()

Void

Jetting
Jetting

Gate Gate (

) Gate



Sprue bush
(Centering)

Gate
Runner
Gate Runner

39
2.2 ()

Weld

strength

Orientation


(
Sprue)

Gate

Gate

40
2.2 ()


undercut
Undercut

(Parting surface)

Over packing

)
: (2539 : 14-5)

(Draft angle)

(Stiffness)

41
2.13
(2550)

6 2548 2548

48 290.45
6.05 74.75
65.82

6 2549 2549

1. 28 97.30

2. 3.47
3. 128.14
4. 78.90
(2550) (Preventive
maintenance : PM)
(MTBF) 68.63%
(MTTR) 22.38 (OEE) 4.85

(2546)
Total productive maintenance (TPM)



TPM
.. 2545 3.46 TPM .. 2545

42
38.01 .. 2546 50.86
TPM TPM 47.40

100 71.44
7 87.97

(2542)
5 .. 2537-.. 2542
3



5
5
Visual foxpro 6.0
Windows 95 Windows 98

(2548) (Preventive
maintenance: PM) (Down time)

218

3

(Down time)
(MTBF) (MTTR)
(OEE)

43

(Down time) 71.18
(MTBF) 152 (MTTR) 32
(OEE) 057
(2549) (Preventive
maintenance: PM)

6
Extruder




100 100
0.4