Methodology for cutting down

lead times in
Dies & Moulds
Presented by Gibson M.
Managing Director
SERMO-ARRK India Pvt. Ltd. Pune

Symposium on Die & Mould Machining, 26-27 June 2008, Bangalore

What is the General Scenario today?

Every customer expects First Trial samples in record time
4 ~ 12 weeks.

DATA & required specifications not frozen ;

Final Data 3D
Final Specifications

Symposium on Die & Mould Machining, 26-27 June 2008, Bangalore

How can we counteract

this reality
and still be successful in
meeting stringent deadlines?

Symposium on Die & Mould Machining, 26-27 June 2008, Bangalore

How can we counteract this scenario ?

Concurrent Engineering techniques.

Development of concurrent engineering emphasizes importance in a

world where reduction of time is always the essence for faster
deliveries.

Use of Computer aided Tools

With introduction of Computer-aided tools, traditional manufacturing

tasks like design, machining & inspection are now highly automated.
However due to complexity & enormous knowledge involved in each
process, a different and practical approach is necessary depending on
the set up of the industry.

Symposium on Die & Mould Machining, 26-27 June 2008, Bangalore

How can we counteract this scenario?

Micro planning methods

Integrate process planning for finish milling & dimensional inspection

of complex surfaces

Optimum production plans - minimize waiting time for any operations.

Optimize available resources.

Symposium on Die & Mould Machining, 26-27 June 2008, Bangalore

How can we counteract this scenario ?

TYPICAL SEQUENCE OF EVENTS ( In case of non availability of Final Data)
1. Use basic CAD/ drawing data available .
2. Make a concept design, preferably 1:1 by sketching process.
i. Plan View
ii. Side view
iii. Decision on ejector pins (with cooling in mind)
3. Optimize on size of raw material
4. Order Material
5. Detailed Planning
i. Macro planning Milling, EDM, hole machining, 2-D operations
ii. Micro planning Concurrent engineering approach
6. Manufacture and assemble as per plan
Symposium on Die & Mould Machining, 26-27 June 2008, Bangalore

DESIGN
1. Simple
2. Sturdy
3. Advanced keep in pace with new technologies
4. Compact try not to over design

Manufacturability -The key consideration.

Symposium on Die & Mould Machining, 26-27 June 2008, Bangalore

PLANNING
1. Analyze the development activities into level of tasks.
2. Evaluate each task for its contribution to the entire process
3. Adjust the process sequence based on inputs & outputs to
& from each task
4. Analyze the relationship & interactions among tasks and
classify into CONCURRENT OR SEQUENTIAL

SEQUENCING - the key consideration.

Symposium on Die & Mould Machining, 26-27 June 2008, Bangalore

MANUFACTURE
1.Micro planning
2.Efficient machining
3.Accurate
4.On time
Precision - the key consideration.
Symposium on Die & Mould Machining, 26-27 June 2008, Bangalore

3-D Core Cavity

Small Parts Lifters / side

cores

Mould Base (SC)

DESIGN
Holes
Cooling lines
Mould Base
(2-D operations added)

Other Parts

Symposium on Die & Mould Machining, 26-27 June 2008, Bangalore

MANUFACTURING
EDM

Assembly

CNC Milling

Polishing

Symposium on Die & Mould Machining, 26-27 June 2008, Bangalore

Successful case studies

Manufacturing- Plastic moulds
CNC Finish machining > EDM parting line and bedding
areas> Assembly bedding > EDM other features >
polishing > final assembly > trials

CNC core machining > EDM lifters, side core areas >
Assembly > EDM other features > polishing ( Cavity
machining in parallel) > final assembly( EDM of cavity) >
Polishing > trials

Symposium on Die & Mould Machining, 26-27 June 2008, Bangalore

KEYS FOR IMPROVING LEAD TIMES

1. Basic Study with all Resource Heads.
2. Micro-planning for operations.
3. Communication between departments/resources with
daily short meetings..
4. Priority planning of resources to meet the above plan.
5. Follow-up.
Symposium on Die & Mould Machining, 26-27 June 2008, Bangalore

FIRST TIME RIGHT

1.

Develop operators to manufacture and inspect before

unloading from the machine.( Check points to be made
available)

2.

No short cuts for approved processes.

3.

Trials to be taken in almost finished condition of Tool/ Die.

4.

Non conformance to be immediately cleared before the First

trial stage as far as possible.

5.

Continuous Training a necessity for all operators for all

improvement processes.
Symposium on Die & Mould Machining, 26-27 June 2008, Bangalore

Few tips to enhance

productivity and
thereby reduce leadtimes
Symposium on Die & Mould Machining, 26-27 June 2008, Bangalore

Design/CAM
Plan parting line area to the minimum required and relieve
other areas in design stage itself.

Avoid sharp cornered parting line joints and create smooth

transitions.

Safe edge in cavities to save damage in polishing.

Symposium on Die & Mould Machining, 26-27 June 2008, Bangalore

MILLING
1. Selection of right cutters
2. Choose the right machine depending on the operations
3. Intelligent programming strategies with Best software for
complex machining.
4. Use of larger dia cutters for better material removal rate
5. Use of proper tools & job holding system -E.g.. Magnetic base
6. Combination of Vertical & Horizontal Machining
7. Use of high feed cutters for better removal rate.

Symposium on Die & Mould Machining, 26-27 June 2008, Bangalore

EDM
1. Selection of Electrode Material (Preferred - graphite )
2. Proper setting /referencing mechanism. Use 3R / Erowa
systems or equivalent.
3. Start with low parameters and end with low parameters to
retain better shape of Electrode.
4.

Design by clubbing electrodes than individual electrodes.

5.

Stable discharge while EDM to improve productivity

6. Use of proper dielectric for flushing with proper flow

7. Use of Side sparking and Orbital cutting.

Symposium on Die & Mould Machining, 26-27 June 2008, Bangalore

General
Develop and have your own standards matching to international
standard parts
Stock all standard parts like wear plates, guide blocks, lifter
rods, slider assemblies for lifters etc.
As far as possible use standard accessories available in the
market locally.
Develop your own suppliers for all standard parts for moulds.
Develop suppliers for milling and turned parts for priority
manufacturing.
Symposium on Die & Mould Machining, 26-27 June 2008, Bangalore

Q & A Time

Symposium on Die & Mould Machining, 26-27 June 2008, Bangalore

Thank you

Symposium on Die & Mould Machining, 26-27 June 2008, Bangalore