2009 Case Studies        

                                                     
Machine # 2

CD-Pillar RH & LH

Established optimum process to reduce rejects and optimize cycle time.
Cycle time reduction from 77 sec to 64.5 sec. Today the LH part is running 77.9 sec.  Mold change preformed to the RH part and we made sure it was running 64.45 sec time
Part weight reduction from 1522 grams to 1490 grams.
Corrected the color streak issues.
Optimized Clamp & Robot sequence.
Established new color change procedure.
 

Lift Gate Lower
Mold # 211-1

Corrected 99% of gas / splay issue by blocking off ribs on the backside of the part.
Reduce 3 operators down to 1 operator.
Optimized Clamp and Robot sequence to reduce cycle time from 104.3 sec to 86 sec. Still time in the robot sequence to save more time. Approximately 5 to 8 seconds.
Reduced part weight from 2367.8 grams to 2324 grams Jet Black total 43 grams.
Reduced rework of the part from 100% to 0%.
 

Short Main Body
Mold # A5633

Reduce Cycle time from 77.4 sec to 64.9 sec.
Potential reduce operators from 2 operators to 1 operator once mold flash issues are corrected.

Spider
Mold # A 5658

Analyze process to reduce cycle time.
95% of the vents were closed. Tooling personnel opened all vents.
Reduced cycle time from 114 sec to 70 sec. This is operator dependent.
Mold has damage and needs to be re-spotted to correct flash condition.
Robot should be reinstated to have consistent cycle.
5’s operator work station to keep gate operator close to gate and on time.

Console End Cap
Mold A 5652

Replaced nozzle on machine to a new mixing nozzle to help with color streaks
Optimized shot size & cushion to prevent burning material in barrel from 10” shot size to 3.5“shot size and cushion from 6.5 “ to .25” cushion.
Reduced cycle time from 54 sec to 42.5 sec
Reduced part weight from 321 grams to 307 grams.

Mold #2 for this machine
Mold Description: HHR Qtr Panel Upper RH & LH
Quality Issues: Flash and Optimize Cycle time
Material: TF 1301 Nat

Reduced Cycle time from 84.6 sec to 71.3 = 13.3 sec reduction.
We changed current process to meet material recommended set points.
Faster fill speed.
Adjusted valve gates to improve flow lines.
Less pack pressure.
Reduced part weight        before             after
                                     RH 1240        RH 1180
                                     LH 1190         LH 1140
Total                             2430gr              2320gr
Total part weight savings = 110 grams
Reduced weld line appearance by moving weld lines to the corners of the window opening.

   What could 3-3-50 do to your bottom line
 

Lower cycle times by                 3%
Reduce part weight by               3%
Cut your Scrap by                     50%

These are the Average Results our Customers see with ZIPPS Services. We can provide these kind of results through consulting service or we can teach your molders how to obtain these kind of documented results. Contact ZIPPS today and see how we can save you money.