Growth of People Growth of Business Manufacturing Cost 1230

Preventive Maintenance Process of Press Die & Injection Mold

Mold
Main Work Execution Responsibility
Work Flow Relevant document Remark
(Dept./Vendor)
Checking-Period -Check Production Qty standard in Mold
History Card Manufacturing(Press , Injection)
Check
-Check final Product Quality level & Mold
problems during the work in advance
Discussing Checking -After discussing the next-period’s Production Management/
Schedule Production Plan & schedule for Checking Manufacturing/ Mold Part
& Maintenance, Fix the final schedule Vendor (Materials Team)
-Send final sample(1EA)(main problem
Moving Mold Manufacturing(Press , Injection)-Manufacturing, Repair
Marking) (Checking)Req. Form
-Assign No. to Manufacturing/Repair Vendor(Materials Team)
-Manufacturing, Repair
(Checking) Req. Form & Dispatch Log (Checking)Dispatch Log

Receiving Request -Assign No. to Manufacturing/Repair Mold Parts

-Manufacturing/Repair
(Checking)Req. Form & Request-Receiving (Checking) Req. Form
of Mold & Request-Receiving Log
-Designate
Log a person in charge of Mold &
-Weekly Work Plan Status
share the content for Checking/Maintenance
Board
of major items and targeted Checking
Checking & schedule
-According to Check Sheet for Checking Mold -Check Sheet for
Maintenance of Mold (P,D / M,D), make Data of existence/non- Mold Parts Checking Mold
existence
-Make sure to consider the problems with (fill in by item)
the final sample & reflect them
Complete -Detailed report on Checking & Maintenance in -Preventive Maintenance
the Mold Manufacturing/Repair(Checking) Req. Mold Parts Checking Log
Checking, & Form & Preventive Maintenance Checking Log -Manufacturing/Repair
Maintenance of -Notify the completion of Checking &
(Checking)Req. Form
Maintenance.
Mold (Sharing Info) -If there is a cost involved in making (manufacturing) -Report for Approval
Parts or outsourcing for purchased goods, proceed
after the basic internal Request for Approval.

Moving Mold -Move to the Line Mold storage Depot Mold Parts
(Attach a tag after completion of
Vendor(Materials Team)
Checking/Maintenance )

Mold Test -After Checking/Maintenance, make sure to Manufacturing & Mold -Mold History Card
test it and organize its result (when problems Parts (Manufacturing)
occur, handle them on the spot)
Mass-
manufacturing
Time Check for abnormality or not
of Quality & Mold
Manufacturing
& Vendor
<Recycle Syste

Growth of People Growth of Business Manufacturing Cost 1230

Mold Repair Process Press Die & Injection Mold

Main Work Execution Responsibility Relevant Document

Work Flow Remark
(Dept./Vendor)
-When there are problems with Mold or Manufacturing (supervisor -Manufacturing/Repair
(Stage 1) Notice Quality, after the Line Stop, notify it (Checking) Req. Form
& manager)
of error-occurrece immediately (wired phone or cell phone) -Manufacturing/Repair
-Fill out Manufacturing/Repair(Checking) Req. (Checking) Dispatch Log
Form & assign No. to Dispatch Log (If it is
emergency, handling first, paper-work later)
(Stage 2) - Repair on the spot or after moving the
Mold Part, decide on the Repair Mold Parts (Responsible -Mold goods inspection -Observance of safety
Receiving the Person & supervisor) standard & sample during the Repair on
- Repair on the spot if it is done within 30 Min or
notice of error- it can be done on the spot. standard the spot
occurrence -After discussing the next-period Production Management/
Production Plan & Checking/Maintenance Manufacturing/ Mold Part
schedule, fix the final schedule Vendor(Materials Team)
-Assign No. to -Manufacturing/
Mold Parts Repair(Checking) Req.
Manufacturing/Repair(Checking) Req. Form & Form & Request-Receiving
request-reception Log Log
(Stage 3) Moving Mold-Send samples for the reference to Repair Manufacturing (Press, Injection)
Vendor(Materials Team)

(Stage 4) Repairing Designate a person in charge of Mold & -Manufacturing/Repair

share the content for repair of major items Mold Parts (Checking) Req. Form
Mold and the targeted schedule -daily Work Plan Status
- Make sure to consider the problems with the
final sample & reflect them Board
-If there is a cost involved in making -Report for Approval
(manufacturing) Parts or outsourcing for purchased
goods, proceed after the basic internal Request
(Stage 5) -Detailed
for report on repair in the Mold
Approval.
Mold Parts
Manufacturing/Repair(Checking) Req. Form
Completion of Mold -Notify repair completion & attach a tag for Repair
Repair completion

(Stage 6) Moving Mold-Move to Line Mold storage Depot Mold Parts

Vendor(Materials Team)

- After the repair, make sure to test it and Manufacturing & -Mold History Card
(stage 7) Mold Test
organize its result (when problems occur, handle Mold Parts (Manufacturing)
Mass- them on the spot)
Time Check for abnormality or not of Manufacturing &
manufacturing Quality & Mold Vendor <Recycle Syste

Growth of People Growth of Business Manufacturing Cost 1230

Mold Spare Parts Management ProcessPress Die & Injection Mold
Responsibility Relevant Document
Work Flow Main Work Execution Remark
(Dept./Vendor)
-When agreeing drawings, structural weakness & LG Electronics/ Mass-manufacturing
Agreement on -Mold drawing
abrasiveness standard
company/ Manufacturing company (LG Electronics Form)
Mold drawings agreement (LG)
manufacturing Spare Parts or not & deciding Qty -LG Electronics Mold Gr
(currently, LG Electronics does not have the -STARION Mold Parts (Mold Manufacturing
standard for Spare Part Management.) spec)
(reference to the warranty period of Mold life)
LG Electronics/ Mass-manufacturing
-If problems occur during the Mold Test company/ Manufacturing company -Test report (LG Electronics Form)
stage, based on the test report, decide the -LG Electronics Mold Gr
manufacturing of additional Spare Parts -STARION Mold Parts

Completion of Mold -After the completion of the approval, when Manufacturing company/ Mass- -Spare Part List (STARION Form)
moving the Mold, transferring/taking over manufacturing company -Spare Part Management Log
approval -STARION Mold Parts -Spare Part Management Log
Spare Parts (based on documents)
Mass- -If mold structural defects occur during the Mass- LG Electronics/Mass- -Minutes of meeting (MOM) (STARION Form)
manufacturing (MP No. 1~ MP No. 3) stages, manufacturing company/
manufacturing (MP based on the MOM, decide the manufacturing of -Counter
Manufacturing company
No.1 ~ 3) additional Spare Parts
1) P,D : 5000~15000 shots -LG Electronics Mold Gr
2) M,D : 5000~10000 shots -STARION Mold Parts
※However, if the fundamental correction of the
problem is not possible, regardless of the
warranty period, take care of it permanently.
-Based on the problems during the regular Mass-
Regular Mass- Mass-manufacturing company -Spare Part Management Log
manufacturing stage, prepare the spare parts for
manufacturing the main (core) parts in advance. -STARION (Spare Part storage box)
--If there is a cost involved in making Manufacturing & Mold Parts -Report for Approval
(manufacturing) Parts or outsourcing for purchased
goods, proceed after the basic internal Request for
Approval.
-During the Preventive Maintenance, conduct the Mass-manufacturing -Spare Part Management
Normal Management maintenance of parts & exchanges of spare parts.. company/ LG Electronics standard (STARION Form)
However, general Maintenance ; Mass- (Manufacturing company) -Spare Part Management
manufacturing company
Log (LG Electronics Form)
regular Maintenance ; Mold Manufacturing -LG Electronics Mold Gr
company -STARION Mold Parts -Mold History Card
(F/U by LG Electronics Mold Gr)

Mass-manufacturing
Maintenance company
Basic -Manufacturing & <Recycle System>
Mold Parts
Management

Growth of People Growth of Business Manufacturing Cost 1230

[Attachment 1] Press Die Preventive Maintenance
Sheet
( )Month [Progress status : (Standby_■) (On progress_◆)
[2013_Mold Group]
Req- Req-
Mold Group Press Die Preventive Maintenance Log (Completion_●)]

Re- Com Progr

re- re- Request Re- Sec-
quest ple- ess Team
cep- cep- Dept. Model Part Name P/N Details of Checking, Maintenance, or Repair spon- tion Remark
ed tion sta- leader
tion tion sibility leader
date date tus
NO date
　 　 　 　 　 　 　 　 　 　 　 　 　 　

　 　 　 　 　 　 　 　 　 　 　 　 　 　

　 　 　 　 　 　 　 　 　 　 　 　 　 　

　 　 　 　 　 　 　 　 　 　 　 　 　 　

　 　 　 　 　 　 　 　 　 　 　 　 　 　

　 　 　 　 　 　 　 　 　 　 　 　 　 　

　 　 　 　 　 　 　 　 　 　 　 　

　 　 　 　 　 　 　 　 　 　 　 　 　 　

　 　 　 　 　 　 　 　 　 　 　 　 　 　

　 　 　 　 　 　 　 　 　 　 　 　 　 　

　 　 　 　 　 　 　 　 　 　 　 　 　 　

　 　 　 　 　 　 　 　 　 　 　 　 　 　

　 　 　 　 　 　 　 　 　 　 　 　 　 　

　 　 　 　 　 　 　 　 　 　 　 　 　 　

　 　 　 　 　 　 　 　 　 　 　 　 　 　

　 　 　 　 　 　 　 　 　 　 　 　 　 　

　 　 　 　 　 　 　 　 　 　 　 　 　 　

　 　 　 　 　 　 　 　 　 　 　 　 　 　

　 　 　 　 　 　 　 　 　 　 　 　 　 　

　 　 　 　 　 　 　 　 　 　 　 　 　 　

　 　 　 　 　 　 　 　 　 　 　 　 　 　

Growth of People Growth of Business Manufacturing Cost 1230

[Attachment 2] Press Die Check Sheet

Model 　 PressLine (Type) 　 Cycle Time (SPM) (Sec) (SPM : ) Remark

Part Name 　 Mold Type 　 Raw material Spec 　 (Check materials-OK / NG) 　 　
Part Number 　 Process 　 Metal plate company/Dept. 　 　 　 　
Mold Manufacturing Total Produc- Machining metal plate workdate/Re-
　 (shot) 　 (Day/ Night) 　 　
company tionQty sponsible Person
Mold Manufacturing Lot Production- Mold Checking date/ Time/ (Date) __ (HR) __ 　 　
　 (shot)
date Qty Responsible Person (Repairing person)______________ 　 　
Category Check Point Checking Method Problem Next checking date Preparation of spare part
1 Is the appearance of Mold (deformation & Bolt-tightening) good? Visual inspection 　 　 　

2 Is the parallelization of top/bottom types good? Visual inspection & steel ruler 　 　 　

3 Is the Guide Set of top/bottom types good? Visual inspection & measuring device 　 　 　

4 Is the mid Guide Pin & Bush good? Visual inspection & measuring device 　 　 　

5 Are the Base Block flatness & parallelization of top/bottom types good? Visual inspection & steel ruler/Oil Stone 　 　 　

6 Are the Holder flatness & parallelization of top/bottom types good? Visual inspection & steel ruler/Oil Stone 　 　 　

7 Are the Stripper flatness & parallelization of top type good? Visual inspection & steel ruler/Oil Stone 　 　 　

8 Is the inside of the Mold clean? Visual inspection 　 　 　

9 Is the bolt-tightening state of parts inside the Mold good? Visual inspection & L-wrench 　 　 　

10 Is the Drawing(Forming) Punch/Die state good? Visual inspection & scraping 　 　

11 Is Trimming Punch/Die state good? Visual inspection & scraping 　 　 　

12 Is Piercing Punch/Die state good? Visual inspection & scraping 　 　 　

13 Is Notching Punch/Die state good? Visual inspection & scraping 　 　 　

14 Is Burring Punch/Die state good? Visual inspection & scraping 　 　 　

15 Is Bending Punch/Die state good? Visual inspection & scraping 　 　 　

16 Is Curling Punch/Die state good? Visual inspection & scraping 　 　 　

17 Is Heaming Punch/Die state good? Visual inspection & scraping 　 　 　

18 Is Marking Punch/Die state good? Visual inspection & scraping 　 　 　

19 Is other plastic area’s Punch/Die state good? Visual inspection & scraping 　 　 　

20 Are all types of Spring(Gas) states good? Visual inspection & tightening vice 　 　 　

21 Is dowel pin-locking state good? Visual inspection & dowel pin disassembly tool 　 　 　

22 Is Stroke End Block state good? Visual inspection 　 　 　

23 Is the setting of Die Height correct? Visual inspection & Height measuring device 　 　 　

24 Is the state of top/bottom type’s Lift & push pin good? Visual inspection & manual operation 　 　 　

25 Are the states of guide gauges for deciding all types of locations good? Visual inspection & manual operation/measuring device 　 　 　

26 Is the state of the System of hydraulic & Air device good? Visual inspection & simple Tester 　 　 　

27 Are the states of Heating & cooling devices good? Visual inspection & simple Tester 　 　 　

28 Is the state of Cam Unit operation good? Visual inspection & manual operation 　 　 　

29 Are the states of Scap device & purge good? Visual inspection & Scrap removal tool 　 　 　

Were 2 pieces inserted for processing & were there any errors for the
30 Metal plate Operator & worker inquiry 　 　 　

correct location?
31 Was there any abnormal noise during the production? Metal plate Operator & worker inquiry 　 　 　

32 Is the purge state of the materials for processing good? Metal plate Operator & worker inquiry 　 　 　

33 Is the matching of press spec against the Mold spec normal? Check total demanding force & Size 　 　 　

remark 　 　 　 　 　

Growth of People Growth of Business Manufacturing Cost 1230

[Attachment 3] Injection Mold Preventive Maintenance Sheet
( )Month [Progress status : (Standby_■) (On progress_◆)
2013_Mold Group]
[

Req- Req-
Mold Group Injection Mold Preventive Maintenance Log (Completion_●)]

Re- Com Progr

re- recep- Request Re- Sec-
quest ple- ess Team
cep- tion Dept. Model Part Name P/N Details of Checking, Maintenance, or Repair spon- tion Remark
ed tion sta- leader
tion date sibility leader
date date tus
NO
　 　 　 　 　 　 　 　 　 　 　 　 　 　

　 　 　 　 　 　 　 　 　 　 　 　 　 　

　 　 　 　 　 　 　 　 　 　 　 　 　 　

　 　 　 　 　 　 　 　 　 　 　 　 　 　

　 　 　 　 　 　 　 　 　 　 　 　 　 　

　 　 　 　 　 　 　 　 　 　 　 　 　 　

　 　 　 　 　 　 　 　 　 　 　 　

　 　 　 　 　 　 　 　 　 　 　 　 　 　

　 　 　 　 　 　 　 　 　 　 　 　 　 　

　 　 　 　 　 　 　 　 　 　 　 　 　 　

　 　 　 　 　 　 　 　 　 　 　 　 　 　

　 　 　 　 　 　 　 　 　 　 　 　 　 　

　 　 　 　 　 　 　 　 　 　 　 　 　 　

　 　 　 　 　 　 　 　 　 　 　 　 　 　

　 　 　 　 　 　 　 　 　 　 　 　 　 　

　 　 　 　 　 　 　 　 　 　 　 　 　 　

　 　 　 　 　 　 　 　 　 　 　 　 　 　

　 　 　 　 　 　 　 　 　 　 　 　 　 　

　 　 　 　 　 　 　 　 　 　 　 　 　 　

　 　 　 　 　 　 　 　 　 　 　 　 　 　

　 　 　 　 　 　 　 　 　 　 　 　 　 　

Growth of People Growth of Business Manufacturing Cost 1230

[Attachment 4] Injection Mold Check Sheet

Model 　 Injection molder 　 Injection molding company/Dept. 　 　 [Preventive Maintenance observance point]

Injection molding work date/Responsible Per- 　

Part Name 　 Mold Type 　 (Day)
son
Part Number 　 Molding material 　 Lot Production Qty (Shot)
(Night)

Mold Manufacturing com- (Sec) 　

　 Gate method 　 Cycle Time & weight (g)
(weight check-OK/NG)
pany
(Date) _
Total Production
Mold Manufacturing
Category Check Point date 　
Qty (Shot) Checking Method
Mold Checking Problem
date/Time/Responsible Person (HR) _(Re-
Correction Next 　checking date Preparation of spare part
1 Is the appearance of Mold good? Visual inspection 　 　 pairer) 　 　

Is the remaining water of the cooling water completely re-

2 Visual inspection & Air Blowing 　 　 　 　
moved?
Was the protection agent applied to the surface of the mir-
3 Visual inspection 　 　 　 　
ror?
4 Are the operation states of fixed-side/operation-side good? Manual operation 　 　 　 　

5 Are the operation side of Slide Core good? Manual operation 　 　 　 　

6 Is the state of Partting Line are good? Visual inspection 　 　 　 　

7 Is the Air Vent are good? Visual inspection 　 　 　 　

8 Is there rust on the molding area? Visual inspection 　 　 　 　

9 Is the Runner, Gate area good? Visual inspection 　 　 　 　

10 Is the operation state of Core Unit in the inclined side good? Manual operation 　 　 　 　

11 Is the operation state of Eject Plate good? Manual operation 　 　 　 　

12 Is the state of Eject Pin & Sleeve good? Manual operation 　 　 　 　

Visual inspection & manual opera-

13 Is the operation state of hydraulic Cylinder good? 　 　 　 　
tion
Visual inspection & manual opera-
14 Is the operation state of Hot Runner good? 　 　 　 　
tion
15 Is cooling water’s Line normal & is there any leakage? Visual inspection 　 　 　 　

16 Are the states of all Pins good? Visual inspection & parallel ruler 　 　 　 　

17 Are the states of all Springs good? Visual inspection & vice tightening 　 　 　 　

18 Is the state of 3-stage operation good? Manual operation 　 　 　 　

19 Is there any Cavity & Core corrosion? Visual inspection 　 　 　 　

20 Is the scraping state of the Interlock area good? Manual operation 　 　 　 　

21 Is the scraping state of the bar Hole area good? Manual operation 　 　 　 　

22 Are the states of all Rivs good? Visual inspection 　 　 　 　

23 Isn’t the resin stuck anywhere? Visual inspection 　 　 　 　

24 Is the state of the Locating Ring good? Visual inspection 　 　 　 　

25 Are there any other problems? Visual inspection 　 　 　 　

Is the spec of injection molder against the spec of Mold

26 Injection work Log check 　 　 　 　
normal?
27 Was the Mold warm-up & the initial temperature checked? Injection Operator&worker inquiry 　 　 　 　

28 Is the state of strange form/purge good? Injection Operator&worker inquiry 　 　 　 　

29 Did it become Over injection? Injection Operator&worker inquiry 　 　 　 　

30 Was there any abnormality or noise? Injection Operator&worker inquiry 　 　 　 　

remark 　 　 　 　 　 　

Growth of People Growth of Business Manufacturing Cost 1230

[Attachment 5] Request of Press Die New / Repair Sheet
2013 Dispatch Log of Request Form [Progress status : (Standby_■) (On progress_◆)
2013_ Mold group]
[
for Manufacturing, modification, repair or processing
Re- Com- Progr
(Completion_●)]

Re- Sec-
Issue Request Repair quest ple- ess Team
Model Part Name P/N Requests spon- tion Remark
NO date Dept. ed tion sta- leader
sibility leader
date date tus
Mold 1)Request for scraping & Checking of the Slide 　 　 　 　 　
1 2/14 GR-182 Top Table MGB000000 2/15 2/16
Group Core on the Operation side
　 　 　 　 　 　 2)Request for the replacement of inclination pin. 　 　 　 　 　 　 　
　 　 　 　 　 　 　 　 　 　 　 　 　 　

　 　 　 　 　 　 　 　 　 　 　 　 　 　

　 　 　 　 　 　 　 　 　 　 　 　 　 　

　 　 　 　 　 　 　 　 　 　 　 　 　 　

　 　 　 　 　 　 　 　 　 　 　 　

　 　 　 　 　 　 　 　 　 　 　 　 　 　

　 　 　 　 　 　 　 　 　 　 　 　 　 　

　 　 　 　 　 　 　 　 　 　 　 　 　 　

　 　 　 　 　 　 　 　 　 　 　 　 　 　

　 　 　 　 　 　 　 　 　 　 　 　 　 　

　 　 　 　 　 　 　 　 　 　 　 　 　 　

　 　 　 　 　 　 　 　 　 　 　 　 　 　

　 　 　 　 　 　 　 　 　 　 　 　 　 　

　 　 　 　 　 　 　 　 　 　 　 　 　 　

　 　 　 　 　 　 　 　 　 　 　 　 　 　

　 　 　 　 　 　 　 　 　 　 　 　 　 　

　 　 　 　 　 　 　 　 　 　 　 　 　 　

　 　 　 　 　 　 　 　 　 　 　 　 　 　

　 　 　 　 　 　 　 　 　 　 　 　 　 　

Growth of People Growth of Business Manufacturing Cost 1230

[Attachment 6] Request of Press Die New / Repair
Sheet

Growth of People Growth of Business Manufacturing Cost 1230

 [Attachment 5] Press Die History Card
Mold Manufacturing History Card

ba- Manage- Biz Division Model Item Drawing No Material Thickness

Used ma- Mold cate- No. of
Cavity No.
Manufac- Manufactur- Acquisition
sic ment No. chine gory Process turer ing date date
Info 　 　 　 　 　 　 　 　 　 　 　 　 　
Moving Responsible Moving Responsible
Date Period Reason for Moving Date Period Reason for Moving
place Person place Person
Mol 　 　 　 　 　 　 　 　 　 　
d 　 　 　 　 　 　 　 　 　 　
mov
e 　 　 　 　 　 　 　 　 　 　
　 　 　 　 　 　 　 　 　 　
　 　 　 　 　 　 　 　 　 　
Year Total Jan Feb Mar Apr May Jun Jul Aug Sept Oct Nov Dec
2010 　 　 　 　 　 　 　 　 　 　 　 　 　
Pro-
duc- 2011 　 　 　 　 　 　 　 　 　 　 　 　 　
tion 2012 　 　 　 　 　 　 　 　 　 　 　 　 　
Qty
2013 　 　 　 　 　 　 　 　 　 　 　 　 　
2014 　 　 　 　 　 　 　 　 　 　 　 　 　
Accumu- Modifica- Modification/Repair details
No cate-
gory
Request
date lated Pro- tion/Repair Total Pro-
duction Qty Written by Remark
duction Qty place A B C D E F Major modification
1 　 　 　 　 　 　 　 　 　 　 　 　 　 　
2 　 　 　 　 　 　 　 　 　 　 　 　 　 　
3 　 　 　 　 　 　 　 　 　 　 　 　 　 　
4 　 　 　 　 　 　 　 　 　 　 　 　 　 　
Mod 5 　 　 　 　 　 　 　 　 　 　 　 　 　 　
ifi- 6 　 　 　 　 　 　 　 　 　 　 　 　 　 　
cati
on/ 7 　 　 　 　 　 　 　 　 　 　 　 　 　 　
re- 8 　 　 　 　 　 　 　 　 　 　 　 　 　 　
pair
de- 9 　 　 　 　 　 　 　 　 　 　 　 　 　 　
tails 10 　 　 　 　 　 　 　 　 　 　 　 　 　 　
11 　 　 　 　 　 　 　 　 　 　 　 　 　 　
12 　 　 　 　 　 　 　 　 　 　 　 　 　 　
13 　 　 　 　 　 　 　 　 　 　 　 　 　 　
14 　 　 　 　 　 　 　 　 　 　 　 　 　 　
15 　 　 　 　 　 　 　 　 　 　 　 　 　 　
A : Change of Product’s appearance shape, B : Change of Product ‘s assembly structure, C : Repair to improve Product’s appearance, D : Repair to improve Product’s size,
E : Repair after Mold damage, F : Others
LG(59) Mold 008 A4 (07.01.09) REV.0

Growth of People Growth of Business Manufacturing Cost 1230

[Attachment 5] Receipt of Press Die New / Repair Sheet
2013 Request-Receiving Log of Request Form for [Progress status : (Standby_■) (On progress_◆)
[2013_Mold Group]
Req- Req- Manufacturing, modification, repair or processing (Completion_●)]

Re- Com Progr

re- re- Re- Sec-
Request quest ple- ess Team
cep- cep- Model Part Name P/N Requests spon- tion Remark
Dept. ed tion sta- leader
tion tion sibility leader
date date tus
NO date
　 　 　 　 　 　 　 　 　 　 　 　 　 　

　 　 　 　 　 　 　 　 　 　 　 　 　 　

　 　 　 　 　 　 　 　 　 　 　 　 　 　

　 　 　 　 　 　 　 　 　 　 　 　 　 　

　 　 　 　 　 　 　 　 　 　 　 　 　 　

　 　 　 　 　 　 　 　 　 　 　 　 　 　

　 　 　 　 　 　 　 　 　 　 　 　

　 　 　 　 　 　 　 　 　 　 　 　 　 　

　 　 　 　 　 　 　 　 　 　 　 　 　 　

　 　 　 　 　 　 　 　 　 　 　 　 　 　

　 　 　 　 　 　 　 　 　 　 　 　 　 　

　 　 　 　 　 　 　 　 　 　 　 　 　 　

　 　 　 　 　 　 　 　 　 　 　 　 　 　

　 　 　 　 　 　 　 　 　 　 　 　 　 　

　 　 　 　 　 　 　 　 　 　 　 　 　 　

　 　 　 　 　 　 　 　 　 　 　 　 　 　

　 　 　 　 　 　 　 　 　 　 　 　 　 　

　 　 　 　 　 　 　 　 　 　 　 　 　 　

　 　 　 　 　 　 　 　 　 　 　 　 　 　

　 　 　 　 　 　 　 　 　 　 　 　 　 　

　 　 　 　 　 　 　 　 　 　 　 　 　 　

Growth of People Growth of Business Manufacturing Cost 1230

[Attachment 9] Press Die Spare Parts Sheet

[2013_Mold Group]
2013 Press Die Spare Parts Management Log 　

Req- Req- Ex-

re- re- Mold Exchange Re-
Production chang Section
cep- cep- Manufacturing Line
Model Part Name P/N Spare Spec. Cycle Max Min
e
sponsi-
leader
Remark
tion tion Dept. (shot) bility
date
NO date
　 　 　 　 　 　 　 　 　 　 　 　 　 　
　
　 　 　 　 　 　 　 　 　 　 　 　 　 　
　
　 　 　 　 　 　 　 　 　 　 　 　 　 　 　

　 　 　 　 　 　 　 　 　 　 　 　 　 　 　

　 　 　 　 　 　 　 　 　 　 　 　 　 　 　

　 　 　 　 　 　 　 　 　 　 　 　 　 　 　

　 　 　 　 　 　 　 　 　 　 　 　 　 　 　

　 　 　 　 　 　 　 　 　 　 　 　 　 　 　

　 　 　 　 　 　 　 　 　 　 　 　 　 　 　

　 　 　 　 　 　 　 　 　 　 　 　 　 　 　

　 　 　 　 　 　 　 　 　 　 　 　 　 　 　

　 　 　 　 　 　 　 　 　 　 　 　 　 　 　

　 　 　 　 　 　 　 　 　 　 　 　 　 　 　

　 　 　 　 　 　 　 　 　 　 　 　 　 　 　

　 　 　 　 　 　 　 　 　 　 　 　 　 　 　

　 　 　 　 　 　 　 　 　 　 　 　 　 　 　

　 　 　 　 　 　 　 　 　 　 　 　 　 　 　

　 　 　 　 　 　 　 　 　 　 　 　 　 　 　

　 　 　 　 　 　 　 　 　 　 　 　 　 　 　

　 　 　 　 　 　 　 　 　 　 　 　 　 　 　

　 　 　 　 　 　 　 　 　 　 　 　 　 　 　

Growth of People Growth of Business Manufacturing Cost 1230

[Attachment 9] Press Die Spare Parts Sheet

Person in Team
Model 42PM45 charge Leader
Item BACK COVER Spare Part List of Mold Part
Sang
Drawing No MCK669298(RA) Cheon 　
Manufactur- Lee
Dong Gu Company
ing company Date : Feb. 14, 2012 / Written by: Seung Il Kwon 　
NO Part Name Process Material Type Size Quantity Unit Price Amount Remark

B12A PUNCH,PIERCING 2/3 　 SJC 3.8*40.5*H5.2 5 12,000 60,000 　

B12B PUNCH,PIERCING 2/3 　 SJC 3.8*40.0*H5.2 5 12,000 60,000 　
B12C PUNCH,PIERCING 2/3 　 SJC 3.8*39.5*H5.2 5 12,000 60,000 　
B12D PUNCH,PIERCING 2/3 　 SJC 3.8*47.5*H5.2 30 12,000 360,000 　
B12E PUNCH,PIERCING 2/3 　 SJC 3.8*47.0*H5.2 30 12,000 360,000 　
B12F PUNCH,PIERCING 2/3 　 SJC 3.8*46.5*H5.2 30 12,000 360,000 　
B12G PUNCH,PIERCING 2/3 　 SJAL 4.2*61.0*3.80*B25*H5.2 16 38,000 608,000 　
B12H PUNCH,PIERCING 2/3 　 SJAL 4.2*62.5*3.80*B25*H5.2 12 38,000 456,000 　
B12I PUNCH,PIERCING 2/3 　 SJAL 4.2*64.0*3.80*B25*H5.2 12 38,000 456,000 　
B12J PUNCH,PIERCING 2/3 　 SJAL 4.2*65.5*3.80*B25*H5.2 12 38,000 456,000 　
　 　 　 　 　 　 　 　 - 　
B12A PUNCH,PIERCING 3/3 　 SJC 3.8*46.5*H5.2 27 12,000 324,000 　
B12B PUNCH,PIERCING 3/3 　 SJC 3.8*47.0*H5.2 27 12,000 324,000 　
B12C PUNCH,PIERCING 3/3 　 SJC 3.8*47.5*H5.2 27 12,000 324,000 　
B12D PUNCH,PIERCING 3/3 　 SJC 3.8*39.5*H5.2 6 12,000 72,000 　
B12E PUNCH,PIERCING 3/3 　 SJC 3.8*40.0*H5.2 6 12,000 72,000 　
B12F PUNCH,PIERCING 3/3 　 SJC 3.8*40.5*H5.2 6 12,000 72,000 　
B12G PUNCH,PIERCING 3/3 　 SJAL 4.2*65.5*3.80*H5.2 13 38,000 494,000 　
B12H PUNCH,PIERCING 3/3 　 SJAL 4.2*64.0*3.80*H5.2 13 38,000 494,000 　
B12I PUNCH,PIERCING 3/3 　 SJAL 4.2*62.5*3.80*H5.2 13 38,000 494,000 　
B12J PUNCH,PIERCING 3/3 　 SJAL 4.2*61.0*3.80*H5.2 18 38,000 684,000 　
Total
　 　 　 　 　 　 6,590,000 　

Growth of People Growth of Business Manufacturing Cost 1230

[Attachment 12] Press Die Spare Part Control Standard

　 　 　 　
Mold Checking Cycle Mold Part Exchange Cycle (Grade
　 　
　 A) 　
Checking
NO Checking Item Remark
Cycle Exchange Material for
1 Molding area 　 NO Part Name
Cycle processing
2 Operation area 　
100,000 1 Piercing Punch&Die 500,000 EGI
3 Fixed area 　
Shot
4 Guide & purge area 　 2 Burring Punch 250,000 EGI
5 Others 　 3 Guide Post/Bushing 500,000 　
Refer-
But, if less than 100,000 shots, check every 3 months 4 Guide Pin&Bush 500,000 　
ence

　 　 5 Coil Spring 300,000 　

Frontal area Re-Grinding Cycle 6 Gas Spring 800,000 　
　 　
7 Gauge Pin 500,000 　
NO Part Name Cycle Remark
8 Lifter Pin 1,000,000 　

1 Piercing Punch&Die 100,000 EGI standard 9 Trimming Punch 800,000 EGI

2 Notching Punch&Die 150,000 〃 10 Notching Punch 800,000 EGI

3 Trimming Punch&Die 150,000 〃 　

4 Cutting Punch&Die 100,000 〃 　
N
5 Sliting Punch&Die 70,000 〃 O
　
T
Refer- Depending on the material for processing, the Re-Grinding E
　
ence Cycle can be changed.
　
Growth of People Growth of Business Manufacturing Cost 1230
 [Attachment 13] Injection Mold Spare Part Control Standard

　 　 　 　
　
Parting Line Scraping Cycle 　
Mold Part Exchange Cycle (Grade
　 A) 　
NO Part Name Cycle Remark
N Exchange Material for
1 Main Core 10,000 　 Part Name
O Cycle processing
2 Slide Core 10,000 　
1 O-Ring 50,000 　
3 Eject Core 10,000 　
2 Coil Spring 50,000 　
　 　 　 　
3 Gas Spring 300,000 　
　 　 　 　
4 Inclination pin 300,000 　

5 Boss Core Pin 200,000 　

　 　
Mold Checking Cycle 6 Guide Post&Bushing 600,000 　
　 　
7 Mold Heater 500,000 　
Checking
NO Checking Item Remark 8 Heater Sensor 500,000 　
Cycle
1 Molding area 　 9 Cooling water Hose 50,000 　

2 Operation area 　 10 One-Touch Nipple 100,000 　

3 Fixed area 20,000 Shot 　 　

4 Guide & purge area 　 　

N
5 Others 　 O
T 　
E
reference But, if less than 20,000 Shots, check every 3 months. 　

　
Growth of People Growth of Business Manufacturing Cost 1230
[Attachment 14] Tag to indicate the completion status of Mold
Manufacturing or Repair (Checking)
The tags below are Changwon standard and according to a subsidiary, the phrase in the local language should be located in the
center.
84mm

In English

In English

In English
Overseas
Subsidiari

Complete
Under Repair
es write it

Repair
in
Standby
Repair

Korean.
193mm

Write it in
the local
Model
language Model Model

Orange Red Green

Growth of People Growth of Business Manufacturing Cost 1230
[Attachment14_1] Tag to indicate the completion status of
Mold Manufacturing or Repair (Checking)

Usage in Sign board

90mm
Changwon Size
Sign board: White background
Letter: HY Gyeon Gothic
Sign board Size : 90*200mm

English
Standby
The same letters in the front/back

Repair
200mm
190mm

MDL

Growth of People Growth of Business Manufacturing Cost 1230

[Attachment 15] Press Die Try Out Procedure

Set Press Die Height (+10mm) Up to 12 o’clock direction comparing with Mold Die Height

Check cleaning status of Press Bolster & Slide and installation Check the locking status Check stroke end block
surface roughtness after clamping (8parts) touch by fine control of
press slide (paper or lead)
Install Check inserting amount of guide
mold Must remove stroke end block post
stopper
Falling after setting press 촌동 (1Step-By- Press is falling
Control press
Step Descent) towards 5 o’clock
slide(Adjust)
direction
Check to see if there is a
Press is rising towards 12 Install mold using the same problem on the parts’
o’clock direction(ascent) method on each process assmbling status and
cleaning status inside on
Check to see if there is a problem on 1) If there is a problema, must
inspect and repair to proceed each process
the parts’ assembling status and Excerpt process simple
cleaning status inside on each process (10ea/process) by inputting material
2) Must check material size sequentially from the primary
1)Press 1Cycle setting
before working on No.11 process.
No.12: Create keynote data comparing domestic 1) Determine direction of revising data Repeat testing & revising
simple standard and measuring the simple product’s standard cycle until basic quality is
floor plan standard size on each process 2) Development, quality, molding, approved
production, _4 departments
Mark(stamping method) on the front
Conduct test to see if there is a problem Matching Test on T.P.L
surface of Die Height’s mold on each
with scrap extraction from punching specification
process after self approval of basic
quality process
1)Operate robot feeding
manually
Identify and revise matching problems Test T.P.L manually 20 times or over after 2) Align arm finger
on T.P.L specification inputting material 3) check the vaccum status of
the arm vacuum pad
Identify/revise final matching problems on T.P.L specification Conduct final mass production verification test and
and molding problems produce sample for approval

Mass produce after revising problems

based on the approval results

Growth of People Growth of Business Manufacturing Cost 1230