Plastics Industry Workshop

Scott R. Kroeger General Manager Husky Injection Molding Systems, Inc. October 2004

8% 4% 22% 22%

2% 4%

A t

tive
60%

Cl s res
C st
53%
rimary Eq ipme t

Large t nnage

19% 6%

E ergy Labor

14% 6%
44%
¤

B il i g & i frastr ct re Mai te a ce

14%

*Excl ding resin

PET
13%

C st
M lder
50% 13%

17%

Pref r s

23%

Typical Costs Drivers

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¢

¢ ¢ ¢

¢£ ¡

¢

6%

¢

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Cost of an Injection
N RGY
9% % % 8% % % 2%

olded Part
% % % 2% %

%

%

% 11%

9%

Mate al Machine Mold Labor Cooling Space ther Energ

Machinery Heat, Vent, A.C. Lighting Chillers Cooling Tower Compressors Grinders Tools Misc.

Source: Demag

Analyzin P T ner y Consu ption .

Machine . . . / h . $ . * At $ .Increased Productivity PET Application Part: Pre or avities Tonna e ner y ( h/ ) yc e Ti e ner y ost or MM units* $ . Additiona Annua Production Units Hydrau ic Hydro echanica A ectric . MM - .

Typical ner y Re uire ents ‡ ‡ ‡ ‡ ‡ Plasticizing Injection Clamp Stroke Core pulls/ejection Idle time 50% 17% 13% 10% 10% Hydraulic Machine .

Electric Screw Drive .

19 1 All Electric Machine .

6 5. 32 cavity closure system Para eter Shot weight Total cycle time Production power nit of Measure g s kW ydraulic Screw Drive 41.81 22.88 26.87 Electric Screw Drive 41.6 5.Ener y Consu ption Co parison 90T.7 Ener y savin s 16% .

16 cavity cup system Para eter nit of Measure g s kW .8 4.2 New Generation -M Machine 113.56 88.39 78.Ener y Consu ption Co parison 300T.5 4.7 Shot weight Total cycle time Production power Ener y savin s 11% .Yr Old -M Machine 117.

Ener y sa e Co parison 00 80 sa e 60 40 20 0-20 40-50 Ener y nd d d u En n ed d u b d Ee ee ve sus h b d s 0-20 on ou e: Fe om kM on e Feb u 2002 ee m 40-50 mp ovemen ove d u .

071 Hyd 9´ p y d d p- US k f 35 : ( 3 ´) = 14.100 S k 5 p p p otal ( S tons Oil ") ons tion [ l ] 1.5 l + stroke cylinders ‡L w ‡L g ‡L g ‡Hg gy p yd p p d p . p p Mold Stroke Oil sa e .9 .

2kw per ton to operate ± HVAC system: $600 per ton of cooling installed + 1kw per ton to operate ‡ Tower water is a more efficient and cost effective cooling method . all-electric machines are completely air cooled e cept for the feed throat ± Requires an efficient HVAC system ‡ Consider typical plant cooling costs: ± Tower water system: $150 per ton of cooling installed + 0.Ener y ± Machine Coolin ‡ Hylectric machine makes use of water cooled motors. gearbo es. hydraulic oil ‡ In most cases. drives.

Enclosed Powerpack Water-Cooled Motors .

.Repeata ility .echanical 90 vs 165 Ton All Electric C v C P n H-M P v g R W g g g . . . .Co parison ydro.

Additional Advanta es of -M Machines ‡ High injection rates .

Electric Injection i itations Instantaneo s Injection o er Accumulator based Hydraulic Injection Current "Practical" Servo Power Limit o er cre ia eter .

500 cc/sec. required .Hi h Output Closure Syste s Injection Rates ‡ 2 X 64 cavity hot runner mold closure mold ‡ 2.

Additional Advanta es ‡ High injection rates ‡ Lower clamp tonnage .

0 3.0 (17% 5.0 6.Test Results ± STM Application MTM Cycle Competitive HydroMachine Mechanical Hybrid Cla p Tonna e Competitive HydroMachine Mechanical Hybrid 8 Closure 100 55 75 100 120 150 90 80 (20% 20 (63% 40 (46% 52 (48% 70 (42% 90 (40% 50 (45% 6.6 (10% 5.0 18.2 (18% 12.8 5.2 (13% 2.5 14.1 (12% Thinwall Dish attery Cover Cell Phone Housin Cell Phone Housin Oval Container Oval id Avera e Savin s 43% 14% .6 (14% 15.0 5.0 10.5 (17% 8.

0 (20% 53.Test Results ± MTM Application Cla p Tonna e Competitive HydroMachine Mechanical Hybrid TM Cycle Competitive HydroMachine Mechanical Hybrid Industrial Container PC a p ezel Fan lade Fan Shroud Infant Car Seat Stora e Tote 1400 1100 1500 1000 750 1000 990 (30% 880 (20% 990 (33% 1000 (0% 650 (13% 800 (20% 69.0 25.5 (24% 44.0 63.0 (20% 63.0 83.1 (9% 20.0 65.0 99.0 62.0 (29% Avera e Savin s 19% 20% .0 (20% 80.

Test Results ± Su ary 95% of applications are tie ar and not tonna e li ited Increasin the tie ar spacin results in ‡ ower tonna e achine re uire ent ‡ ower ener y re uire ents ‡Maxi ized floor space ‡Faster cycle ti es .

Macro evel ± Factory Efficiency .

Efficient Factories ‡ Methodically Implement Innovation ‡ Establish a base of reliable and repeatable molding ‡ ‡ ‡ ‡ equipment Eliminate e ternal influences on molding processes Rely on stable and robust infrastructure Automate to eliminate variation Establish and maintain ± ± ± ± Tooling/workcell standards Quick mold change procedures Optimal molding recipes Maintenance procedures ‡ Mold unattended-using SPC to ensure quality control .

Opti ize Factory ayout and Equip ent ‡ Re-Think the machine cell and factory layout ± When selecting machines look for ways to improve system output ‡ Hydraulic services to the mold ± Au iliary power units may be required ‡ Stack Molds ‡ Machine automation ‡ Mold design / ma imize cooling ‡ Part Design ± Minimize the number of systems required ± Eliminate secondary operations ‡ Consolidation of Parts ‡ Multi-material ‡ IML .

Efficient Factories ‡ Create healthy work environments ‡ Establish and follow best practices ± ± ± ± Environmental health and safety Air quality Lighting Noise .

heoretical hro ghput hroughput © ¨ § © ¨ § o or ) Idle Ca itie a bloc e d hroughput Running Machine State Factor Im acting Equipment Factory hroughput Impacting Eq i ment ro g t Factory Efficiency-Standard Definition        ¦   © ¦ ¦ Faulted n c e d led cheduled do ntime   ¨¥   ¥   ¨  ¦ ¥ ¦ ¥ n a ailable erall Factory Efficiency FE) = Scheduled Sc e d led do n Mold change c a nge lanned hroughput ro g t erall Eq i ment Efficiency Equipment EE) = Cycle ariance roducing crap ) ctual ct al hroughput ro g t rod c ing oducing a rt good part ) .

Factory Desi n as a Syste ‡ ‡ ‡ ‡ ‡ Ma imizes Factory Efficiency Optimizes equipment utilization Raises automation levels Drives process / product consistency Integrates processes to reduce energy consumption ‡ Allows for fle ibility and easy e pansion .

Factory Plannin Services Factory Audits Continuous Improvement Manufacturing Planning Design & Engineering Project Management .

900. inventory levels Reduction to 1 hour average TOTAL PLANT SAFETY Plant Safety $935.000 $560.000 o ts THROUGHPUT Efficiency Gains Scrap Reduction Cycle Improvement OEE Improvement by 5% reduction by 1% 5% improved average cycle time TOTAL OPERATIONAL Labor reduction Energy efficiency Inventory Levels Mold Change Time $900.000 $125.000 Reduced WC premiums TOTAL $1.000 .000 $100.000 $50. chiller replacement 20% reduction in av.000 reduction of 4 people per shift Pump upgrade.000 $150.000 $400.Factory Audits ‡ ‡ ‡ ‡ ‡ Instrument & Analyze e isting operations Establish current factory efficiency Quantify improvement opportunities Report on findings and recommendations Compare performance benchmarks ro t Ar a ortu ity yr $400.000 $100.

environment. & order X 8 Total plant efficiency (TPE) X )3 6 4 )3 2 o e sure ore "  tin s oor ver e e ent 9 0 # 8 7 ) (' " % eo ver e ove ver e   &% % te ______________ nt ssess ent or s eet e tin nt ________________ est in ss ores 5 " % $ # " ! 45 55 65 75 85 95 @5 A5 B5 C5 46 5 6 7 8 9 @ A B C 1   .I prove ent Opportunities 6 Teamwork and Motivation X 6 Information Systems X 6 Maintenance standards X 7 Conditions and maintenance of equipment and tools X 6 Commitment to quality X 6 Mold change efficiency X 6 Levels of automation X 6 Labor productivity X 8 On time deliveries X 5 Inventories X 7 Product Flow and Use of space X 7 Process services X 8 Resin Handling System X 6 Level of standardization X 5 Visual Management X 7 Equipment reliability X 6 Scrap rates X 8 X 7 Overall Equipment Efficiency (OEE) Safety. cleanliness.

Factory Plannin Services Factory Audits Continuous Improvement Manufacturing Planning Design & Engineering Project Management .

. . volumes & schedules Compare primary equipment strategies Define infrastructure requirements Simulate impact of layout alternatives Shipment y Product Category al an a nalit Sales Sales ve . . . lat Demand dQQd QQd eQQd QQQd 1- QQQ QQR 7. I HF E D G F E D QQQ QQQ T QQQ QQR T QQQ QQR P QQQ QQQ S QQQ QQQ P c ab . QQQ QQR S QQQ QQQ R . ov em ec em Ja nu Se pt D Months e ` U ` VY V V X V W V ly ar y ar y us t ar ch Ju pr ug em ct o ru Ju ne er er er il ay er U QQQ QQR R a Estimat Monthl Volum . . . . . . . . .Manufacturin Plannin ‡ ‡ ‡ ‡ Review product matri . g f QQQ QQQ 7. . . .

CO O aw aterials Flow rimary quipment upporting reas Desi n Considerations –y — w w v – y € € •x wx •wv ƒ x v xxw v€ ” v ƒ €• – ™„ ” „ de fe gfhie – ƒ ”v – wvx€ xwv „€€ ƒx‚ ˜ w y ƒyw y ƒ” ih uvt rspq „ ƒ ”v vw„w th qhu – y„x™wvƒ• ”v „ ƒ y ƒ• w ” xvw  –y „  ervices Distribution I I OU …“ ˆ ‡ … / …“ ˆ ‡ … de ef gfhie TO TO ˜ „x „x „x „x or sr o qp o jm nm j j lk ‰‘…“‰ ˆ‡’† … IN .I N BU F F ‘…“ ˆ ‡ … F UT U X N IO N C I I ost old Operations .achine all ayout F UT U X N I N Finished roducts Flow UTU F UT U X N IO N I INK C I T W INK C IC B OW O IN W I C I O C T IC OO IN I O I O T FO IN T I O I N IN I C IN I T C U T CI I TI I .I N BU F F IN .

Benefits of Manufacturin Plannin ‡ Define long term strategy to guide short term decisions ‡ Quantify the impact of manufacturing alternatives ‡ Benchmark e isting operations against current technologies .

Factory Desi n as a Syste Factory Audits Continuous Improvement Manufacturing Planning Design & Engineering Project Management .

Desi n and En ineerin ‡ ‡ ‡ ‡ Building and process mechanical systems Resin handling and distribution Environmental control systems Mold change alternatives .

Displacement Ventilation + Floor Cooling Using free cooling +Heat Recovery+ Dehumidification a se se se se D se E Sys e Sys e Sys e Desi n and En ineerin Desi n and En ineerin Š ‰ Š ‰ ŽŠ ‰ Š ‰ ˆ‡ Š ‰ ˆ ‡  Š ‰ ˆ‡ Œ Š ‰ ˆ‡ ‹ Š ‰ ˆ‡ Dehum. era i n š™ ss |{ } z} | ~~ z~ | z} z | {z y x w nn a era i n ss r di eren n e s € €€€‚ € €€€‚ €€ƒ  €€€‚ €ƒ  €€€‚ €€„ €€€‚ €„ €€€‚ €€… €€€‚ €… €€€‚ €€† ”• “ ”“ ’‘ ˜ —– % .

Benefits of Desi n and En ineerin ‡ Integrate building and molding process ‡ ‡ ‡ ‡ requirements Lower overall energy consumption Provide reliability and redundancy Seamless e pansion capability Identity interferences prior to installation .

Factory Desi n as a Syste Factory Audits Continuous Improvement Manufacturing Planning Design & Engineering Project Management .

Continuous I prove ent ‡ Define key performance indicators ‡ Prioritize factory optimization programs ‡ Project manage implementation .

Methodically I ple ent Innovation .

Methodically I ple ent Innovation .

A 1 A 2 Multi Mold Carrier Technolo y .

Auto ate to Eli inate ariation Pro ra a le cranes to auto ate aterial handlin .

Area Gantry Ro ot ± provides consistency in packa in .

redundancy. reliability. seamless e pansion .Esta lish and Maintain Standards ‡ Manufacturing Process .Work Instructions ± ± ± ± ± ± ± ± ± ± ± Scheduling Mold change procedures Molding recipes Maintenance practices Work flow Runner Systems Gating Cavitation Barrel / Clamp combinations Quick mold change provisions Automation ‡ Tooling / Workcell Designs ‡ Infrastructure ± Consistency.

' T erm'ts Sprue/ In se rt Electrical Drop Grinder Raw Material Grinder Raw Material SER ICE ZONE Resin Workcell Standards .PROD CT REMO AL ZONE Packaging/Access to Product Aisle Packaging/Access to Product Aisle Automation/ Secondary Ops/ Conveyor Mold Drop/ Staging Area Automation/ Secondary Ops/ Conveyor Service Manifo ld Drops Controller T erm'ts Sprue/ Insert Access Aisle ( 3' .

average 60% utilization 1 common machine Molds fle ible to machine .average 80% utilization .Machine Standardization 30% 30% 30% 30% 30% 30% 30% 30% 30% 30% 30% 30% 30% 30% 30% 30% 60% 60% 60% 60% 90% 90% 60% 4 different machines Molds dedicated to machine .

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Case Studies
‡ ‡ ‡ ‡ ‡ ‡
Water Bottler Medical Thinwall Molder Custom Molder PET Preform Molder Transportation Products China Factory

Water Bottler Asia Pacific)

000 Sq/ft facility in less than one year .Case Study-Water Bottler Asia Pacific) O jective ‡ E pand the plant while overcoming major challenges such as: ‡ Remote location ‡ Logistics for shipping high volume output ‡ Lack of electrical and sanitary infrastructure Approach ‡ Develop long-term manufacturing strategy and implementation plan Results ‡ Seamless e pansion capability ‡ Self-generating power facility (Cogen ready with e pansion) ‡ Bio-filtration system ‡ Closed cooling system to eliminate losses from evaporation ‡ Plant and infrastructure layout allowing 10 times more output ‡ Delivered a 110.

Medical Thinwall Molder North America) .

process infrastructure and overhead cranes ‡ Plant upgrades completed in eights weeks .Case Study-Medical Thinwall Molder North America) O jective ‡ Launch a new line of products in response to off-shore pricing competition Approach ‡ Upgrade the e isting facility to realize performance capabilities of new machines Results ‡ Optimal plant layout allowing workcell automation ‡ Detailed specifications for floor slabs.

Custom Molder North America) .

waste heat recovery. displacement ventilation.Case Study-Custom Molder North America) O jective ‡ Design a low-emissions facility which incorporates energy conserving technologies Approach ‡ Photovoltaic cells generate 45 KVA of electricity ‡ Natural ventilation and day lighting. building technology and energy conservation . in-floor radiant heating and cooling ‡ Treatment of all waste water through biological filters Results ‡ Manufacturing fle ibility was assured with a machine hall free of columns ‡ Infrastructure and material handling were distributed through a full basement ‡ Facility ma imizes efficiency with the integration of manufacturing automation.

PET Preform Molder North America) .

Analyzin PET Ener y Consumption .

Case Study-PET Preform Molder North America) O jective ‡ Construct a high output preform manufacturing center in si months Approach ‡ Established layout and technical specifications ‡ Created master schedule that outlined critical equipment and construction elements ‡ Centralized dehumidification system ‡ Unique (small volume) molding hall design Results ‡ Molded first part 6 months after kick-off meeting ‡ Coupled HVAC and process systems to optimize energy consumption ‡ 3D process system design allowed pre-fabrication of pipe sections reducing installation time-ready for seamless e pansion .

Transportation Products North America) .

insulated enclosure outside the building envelope ‡ Floor slabs replaced to support up to 1000 ton machines ‡ Over head crane allows safe quick mold change and handling ‡ Project completed prior to si month launch deadline . light duty manufacturing facility to high performance molding operation Result ‡ Process mechanical system designed and delivered in a prefabricated.Case Study-Transportation Products North America) O jective: ‡ Launch new injection molding product line to replace SMC thermoforming Approach ‡ Convert e isting small foot print.

.

Ener y Concept±Summer Mode .

Factory Plannin Ma imizing Factory Efficiency © 2003 Husky Injection Moldin Systems LTD .

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