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INJECTION MOLDING ENERGY CONSERVATION SEMINAR:MODERN INJECTION MOLDINGDavid O.Kazmer,P.E.,Ph.D.Northeast Utilities Auditorium,Berlin,CTINJECTION MOLDING ENERGY CONSE1Economics 101=Energy Conservation 101?Adam SmithWealth of Nations,1776Each individual intending only his own gain must exchange what he owns or produces with othersBy division of labor and a free market,public interest is advanced.Does this“invisible hand”serve energy conservation?Economics 101=Energy Conserv2$0.25/serving$0.20/serving$0.35/serving$0.87/serving“Lets Play The Price Is Right”Economic choices are usually rationalRole of government to provide transfer prices and incentives$0.25/serving$0.20/serving$0.33AgendaModern Molding TechnologiesEconomic Structures&DataEvaluation of Injection Molding Class 0:ObsoleteClass 1:StandardClass 2:EfficientClass 3:Lights OutCompetitive StrategiesConclusionsAgendaModern Molding Technolog4Molding Technologies:Modular MoldsModularity&standardization have providedReduced design time&mold tooling costs10 minute quick change in pressTrend reversalCheap moldsPrototype moldsLower importance of quick change givenexcess capacityMolding Technologies:Modular 5Molding Technologies:All Electric MachinesAll electric advantages50%of the powerSilent operationCleanlinessPrecisionReduced AC costsTrend to continueAutomotive hybrids fuel motor technologyAsian machine technology improvesMolding Technologies:All Elec6Molding Technologies:Hot RunnersMelt delivery systems provide:Low pressure dropsFast cycle timesZero material wasteTight quality controlTrend to continue:Lower priced systemsNew technologiesEconomic decisionsMolding Technologies:Hot Runn7Molding Technologies:Cavity Pressure ControlClosed loop pressure feedback provides:Automatic V/P switchoverImproved consistencyQuality control dataTrend to continue:Low cost sensorsCheap computersNew technologiesImproved controlImproved sensingMolding Technologies:Cavity P8Modern ManufacturingModern Manufacturing9Molding Technologies:AutomationRobotics provides for:Reduced labor content(demolding°ating)Repeatable cycle timesFast cycle timesTrend to continue:Cheap computersLow cost motors&standard designsMolding Technologies:Automati10Molding Technologies:Quality ControlQuality control systems should enable:Automatic acceptance or rejection100%part testingAutomatic cyclingVariance analysisTrend to grow:SPC is crudeSensor:analysis explosionImproved capabilities Molding Technologies:Quality 11Molding Technologies:Electronic Data SystemsElectronic data systems should enable:Production schedulingMaterials requirements planningReal time plant feedbackReal time process feedbackTrend to grow:Networked supply chainsScience-based productsAggressive competitorsMolding Technologies:Electron12Molding Technologies:OthersCoinjectionDynamic feedGas assistIn-mold assemblyIn-mold colorIn-mold filmIn-mold paintingInsert moldingLost core moldingMold filling analysisMuCellPad printingPulsed heatingRapid prototypingStack moldsThin wallTwo-shot moldingWater assistMolding Technologies:OthersCo13AgendaModern Molding TechnologiesEconomic Structures&DataEvaluation of Injection Molding Class 0:ObsoleteClass 1:StandardClass 2:EfficientClass 3:Lights OutCompetitive StrategiesConclusionsAgendaModern Molding Technolog14Cost StructuresTotalProduction CostsTotalLabor CostsTotalConsumables CostTotalFacilities CostsMachineryMaintnceFacilitiesYield$/HrOutputDowntimeEnergyResinCost StructuresTotalProductio15Cost ParametersCost parameters N.E.ChinaOperator labor$13/hr$0.70/hrEng/Mgt labor$30/hr$3/hrEnergy cost$0.08/kWhABS resin$1477/ton$950/tonMachinery cost$30/hr$15/hrFacilities cost$7.00/ft2$4.20/ft2Maintenance rate10%20%Cost ParametersCost parameters16AgendaModern Molding TechnologiesEconomic Structures&DataEvaluation of Injection Molding Class 0:ObsoleteClass 1:StandardClass 2:EfficientClass 3:Lights OutCompetitive StrategiesConclusionsAgendaModern Molding Technolog17Evaluation of Injection Molding Case Study for a Mid-Sized Molder200 million parts per yearAverage part weight:10gEvaluation of Injection Moldin18Class 0:ObsoleteOperating Conditions8 cavities/mold with cold runnersPoorly selected hydraulic machines(26 kW)50 seconds per cycle(optimistic)Cooling issues&semi-automatic95%quality level(optimistic)1 operator per 1 machine1 eng/mgt per 15 operators2 shifts,5 days per week4 hour setup per 10,000 partsClass 0:ObsoleteOperating Co19Class 0:ObsoleteFactory Characteristics#Operators#Machines#Eng/MgtEnergy UseClass 0:ObsoleteFactory Char20Class 0:ObsoleteCost DataClass 0:ObsoleteCost Data21Class 1:StandardOperating Conditions16 cavities/mold with 50%hot runnersWell selected hydraulic machines(30 kW)45 seconds per cycle(optimistic)98%quality level(optimistic)1 operator per 2 machines1 eng/mgt per 15 operators2 shifts,5 days per week2 hour setup per 10,000 partsClass 1:StandardOperating Co22Class 1:StandardFactory Characteristics#Operators#Machines#Eng/MgtEnergy UseClass 1:StandardFactory Char23Class 1:StandardCost DataClass 1:StandardCost Data24Class 2:EfficientOperating Conditions32 cavities/mold with hot runnersElectric machines(26 kW)40 seconds per cycle,fully automatic99%quality level1 operator per 4 machine1 eng/mgt per 15 operators3 shifts,5 days per week1 hour setup per 10,000 partsClass 2:EfficientOperating C25Class 2:EfficientFactory Characteristics#Operators#Machines#Eng/MgtEnergy UseClass 2:EfficientFactory Cha26Class 2:EfficientCost DataClass 2:EfficientCost Data27Class 3:Lights OutOperating Conditions32 cavities/mold with hot runnersElectric machines(22 kW)35 seconds per cycle Fully automatic including crating,etc.99.9%quality level1 operator per all machines1 eng/mgt per all machines3 shifts,7 days per week0.5 hour setup per 10,000 partsClass 3:Lights OutOperating 28Class 3:Lights OutFactory Characteristics#Operators#Machines#Eng/MgtEnergy UseClass 3:Lights OutFactory Ch29Class 3:Lights OutCost DataClass 3:Lights OutCost Data30ComparisonNew EnglandChinaComparisonNew EnglandChina31Head to Head Competitive AssessmentHead to Head Competitive Asse32Validation:World ProductionUS Plastics industry went from surplus of$894 million in 2000 to a deficit of$1,387 million in 2002A swing of$2,281 million.In 2001,China exported$6bn of fabricated plastic products last year.China also exports plastics in many other formsIn 2002 China doubled the volume of its exportsChina is worlds largest petrochemical importerChinese petrochemical demand is doubling every 8 years.Validation:World ProductionU33Validation:Plastic BagsIn 2003,US imported more than 100bn plastic bagsA 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 dutyIn 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 value.A producer of plastic utensils found that they could purchase products from China for less than the cost of their resin.Validation:Plastic BagsIn 20034AgendaModern Molding TechnologiesEconomic Structures&DataEvaluation of Injection Molding Class 0:ObsoleteClass 1:StandardClass 2:EfficientClass 3:Lights OutCompetitive StrategiesConclusionsAgendaModern Molding Technolog35Competitive Strategies:Best Way Not to CompeteDont be an average custom molderNon-optimal,semi-auto cyclesLow,variable production quantitiesHigh labor contentMaterial cost disadvantagesHigher volume jobs going overseasLower volume jobs going to short run prototype shopsMiddle volume jobs are scarce and cheapCompetitive Strategies:Best W36Competitive Strategies:Product Specialization Research indicates plastic parts are 10-40%of product valueValue is retained if vertically integratedOutsourced suppliers typically recoup 5-10%Processors should focus on productsVertical integration allows tight integration between market,design,and processingProduct technology&IP raises barriers to competitionCompetitive Strategies:Produc37Product Specialization Case StudyHead up displaymakerInternal molder$15 reflector0.25”Thick100 sec cycleVery highretained profitOther example:Visteon&HVAC UnitsOther example:Nypro&cell phonesProduct Specialization Case S38Competitive Strategies:Process Specialization Focus on advanced processesTechnology allows new capabilitiesInvestment,know how,and IP provides barriers for competitionProcess focus can lead to a market nicheMarket niche provides greater recognition with better,more confident serviceCompetitive Strategies:Proces39Process Specialization Case StudyProto-moldAutomated quote,design,build,mold$=f(Q,t)Suggested changesParts in 5 days100-10,000 qty$7.00-$3.00 vs.$0.40 in commodity marketOther example:NAL&Stanley in auto lightingUse of multi-shot moldingProcess Specialization Case S40AgendaModern Molding TechnologiesEconomic Structures&DataEvaluation of Injection Molding Class 0:ObsoleteClass 1:StandardClass 2:EfficientClass 3:Lights OutCompetitive StrategiesConclusionsAgendaModern Molding Technolog41ConclusionsCompetitiveness isnt all about labor ratesAutomation&localization can largely offsetTrue commodities(bags)in jeopardy?It is about efficiency Knowing which/how to leverage technology and differentiationMarket understanding,penetration,&recognitionProduct&process specializationCost&time performanceConclusionsCompetitiveness isn42Final ThoughtsMid-Term Issue:Oil&Natural Gas SupplyIncreasing Asian demandWeakening dollarGovernment debtTrade deficitEuro as preferred currencyLong-Term:Labor DemandGlobal supply of all laborImproving supply chainsFinal ThoughtsMid-Term Issue:43
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