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[Injection Section]

Model Change Standard

Manual


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Electronic industry during the Digital Age has shortened the Life Cycle of the product dramatically,

and in a situation where prices change quickly, continuously introducing new products and reflecting

the needs of various customer has been prioritized as the main factor for the companys survival.

Especially, the increase of material cost due to recent Won currency boost and high petrol cost, the

cost price pressure is growing, Japanese companies efforts, thanks to the structure adjustment and

internal economic recovery, are concentrating on strengthening their expansion on their lead in the

market.

Our company must playing the leading role, by establishing a rational Process in order to expand

the cost and speed competitiveness.

Especially, as for our company and vendors in which the foundation is based on increase in

production amount, production system operation of various products variable, On time 3 Days Fixed

Production Plan, Fixed amount production, we must ensure that the company and vendors Model

Change time be shortened in order to achieve a World Class Corporate.

In such aspects, we would like to provide the drive methods to improve the people involved by

themselves at the manufacturing site, by making use of the Press Equipment Model Change Standard

Manual. The purpose for developing this Press Equipment Model Change Standard Manual is :

First, Speed insurance through Model Change Time Single Systemization.

Second, Improve Operation Rate and Capa. through Model Change time shorten.

Third, Establish an Effective Factory through Standardizing Model Change Work Process

and Improvements.

The core capability in the Electronic industry is speed.

I believe that this Press Equipment Model Change Standard Manual is a compulsory guide to

achieve the World Class Corporate.

Through continuous improvements and preservation, we request for your active usage to create a

competitive factory.

September 2006

Corporate Business Innovation Team

Vice President Yoon Ju Hwa

Introduction


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. Check List

. Overview

. Model Change Work Order

Attachment Documents

Attachment 1.

Improvement steps for Model Change Single

Systemization

Attachment 2.

Model Change Work Improvement Point

Attachment 3.

Improvement Cases

Content


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Check List


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1. Outer Preparation Check

2 Inner Check List

Ejection Model Change Standard Manual


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2. Inner Preparation Check List

3. Outer Preparation Check List



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Standard Work Order Management PointStd

Time(s)Ref.

01 Obtain Production Plan from the Supervisor 30mins before work -Page 9

02 Create Model Change Chart 20 mins before work 30003 Go to Mould Storage Area with the Hoist 90 mins before Model Change 30

Page 1004Find the Mould for Model Change and Connect tothe Hoist

Appoint Mould StorageAddress

30

05Move the mould for Model Change to Pre-HeatingWaiting Area

Locate Pre-Heater nearInjection Machine

120

09Find the Appropriate Tool Cart from the ToolStorage

10 mins before Model Change 30Page 14

10 Move the Tools Cart to the Facility Area Store Tools in Tool Storage 60



Time(s)Ref.

01 Swith Injection Machine to Manual and stop Mesasure Model Change Time -

Page 1902 Switch OFF the Heater Controller Power 203

Use Injection Machine Nozzle Lever to RetreatNozzle

Standardize Nozzle RetreatDistance

2

04 Open Injection Machine Front Safety Door 5Page 20

05 Apply Grease on the Mould Surface Maintain Rust, Core Parts 15

09After applying Grease, Check for Errors onInner Mould

5

Page 2310 Close the Mould Manually Check PIC B Completion 5

11 Lower Hoist onto Mould 20

16 Connect Hoist and Mould Make the rope tight 5 Page 25

17 Release Auto Clamp Pressure 10

Page 2618 Separate the Gasket 10

19 Separate 2 fixed side, 2 moving side clamps 10

21 Open Injection Machine's Moving Plate Manually 10Page 2822

Separate Production Complete Mould fromInjection Machine

Beware of Locate Ring Damange 5

23 M ove Production Complete Mould to Assigned Area Add Legs to Mould 50

27 Separate Hoist from Production Complete Mould 15

Page 3028 Connect Hoist to Model Change Model Check Eye-Bolt Connection 15

29 Move Model Change Mould to Injection Machine 20

30 Lower Model Change Mould to Injection Machine 30

Page 3131 Stick Locate Ring to Injection Machine 30

32 Center Mould Locate Ring and Injection Nozzle Indicate Center 15

35 Close Auto Clamp to Mould Check Mould Plate Thickness 10Page 33

36 Switch ON and Fix Auto Clamp Control Box 10

39 Lower Hoist and Loosen the Line 10

Page 3542 Move Hoist to Production Complete MouldLocation 20

47 Open Injection Machine Front Safety Door 5Page 38

48 Clean Grease on Inner Mould Prepare Hand Rug 30

52 Forward Injection Machine Cylinder 12

Page 4053 Squeeze out Over-Heated Resin inside NozzleCheck Resin Residue inside

Mould30

54 Switch Injection Machine to Semi-Auto 5

55 Adjust Detail Injection Conditions 5

Page 4156 Inspect until Production Inspection Standard 120

57 Record Model Change Time -


Time(s)

Ref.

22 Indicate Completion on Model Change Chart 20Page 42

23 Move model change cart to waiting area 60


1

PIC A Check List



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Standard Work Process Management PointStd.

Time (s)Ref.

06 Connect the Mould for Model Change to Pre-Heater Before (Pre-Heating Time + 10mins) 60

Page 1207Check Pre-Heater's Temperature Setting andCheck For Leaks

Mould Temperature +% 30

08After Connecting the Valve Gate Heater, Set theTemperature

Melting Temperature 90% 40

11 Move the Hoist to the Pre-Heating Mould 10 mins before Model Change 60

Page 1512 Separate the Pre-Heater from the Mould Check Mould Temperature 10

13 Off the Heater Power and Disconnect the Wires 10

14 Connect the Pre-Heated Mould to the Hoist Check Eye-Bolt Connection 10Page 16

15Move the Pre-Heated Mould to the Model ChangeInjection Machine

Appoint Mould Waiting Area 300

16 Separate the Pre-Heated Mould from the Hoist 10Page 17

17 Move the Hoist to the Upper Injection Machine Indicate Center Indication 30

18 Close Production Mould Coolant In/Out Valve 3 mins before Model Change 5

Page 1819 Open the Air Out Valve Standard Valve color 5

20 Supply Air and Remove Coolant Residue Check Coolant Removal 60

Standard Work Process Management PointStd.

Time (s)Ref.

06 Open Injection Machine Back Safety Door 5

Page 2107 Separate Coolant Hose on Fixed Side 10

08 Separate Coolant Hose on Moving Side 10

12 Separate Heater Connector Standardize Connector Pin 10

Page 2413 Separate Air hose 10

14 Separate Timer Wire 1015 Connect Production Complete Mould to Hoist Check Eye-Bolt Connection 15 Page 25

20 Separate Clamp upon PIC A's Signal 10 Page 27

24Check the Model of the Model Change mould fromInjection Machine

Check Injection ConditionInput

30

Page 2925 After Model Check, Retrieve Injection Condition 5

26 Check Injection Condition of Model Change Mould 25

33 Input Gas Conditions of Model Change Mould 30Page 32

34 Check and Adjust Heater Supplier 30

35 Close Auto Clamp to Mould Check Mould Plate Thickness 10Page 33

36 Switch ON and Fix Auto Clamp Control Box 10

37 Connect Fixed Side Coolant Host Check Cooling Block 15Page 34

38 Connect Moving Side Coolant Hose Check In/Out Connection 1540 Separate Hoist from Mould 15 Page 35

42 Adjust Mould Thickness in Injection Control Panel 20Page 36

43 Open Mould 5

44 Climb Up Injection Machine and Connect Wires 10

Page 3745 Connect Air Hose Check Air Supply 10

46 Connect Timer Wire 10

49 Set Injection Machine Cooling ConditionsStandardize Surrounding

Components per Equipment10

Page 3950 Set Heating Conditions 10

51 Set Gas Supplier Conditions 10

Standard Work Process Management Point Std. Time(s) Ref.

21 Move Proudction Complete Mould to Mould Storage 300 Page 42

2

1. Outer PreparationCheck List



PIC B Check List



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Overview

Definition of Model Change

. Purpose of Model Change

. Target of Model Change

. Methods of Model Change

5. Preparation for Model Change Single

Systemization

6. Understanding Injection Structure


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Time taken to complete the current production and

producing a product after changing the model

Product Standard : A product which passes the inspection

based on Inspection Standards

Creating a Flexible manufacturing site producing quantity in

accordance to the selling speed, establishing fixed time,

fixed quantity structure through Supply Management Process

Shorten Manufacture Lead Time

Reduce ManufacutureStorage

Improve Operation Rate (Improve Model Change Loss : Preparation,

replacement, adjustment etc.)

3



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Item Preparation Standard Method Ref.

Equip.

Install Auto

Clamp(QMC)- Upon vendor approval and purchasing new

injection machine, appoint as compulsory clause

Page

26,33

Create Channel forLocate Ring Center

- Standardize locate ring height- Create locate ring guide for injection machine

fixed side

Page

69

Display MouldCondition Chart

- Find the conditions for optimum production,create condition chart and manage by displayingit on site

Mould

Install CoolantAssemble Block

- Manufacture cooling assble block during mouldproductionInclude this clause as compulsory upon mould

approval

Page

22,34

Standardize EjectorPIn Location

- Standardize Ejector Hole Location per mouldInclude this clause as compulsory upon mould

approvalPage36

Standardize MouldFixed PlateThickness

- Standarize mould fixed plate thickness accordingto Clamp(QMC) standard (Manufacture additional T-Block if needed)

Page

33

Indicate MouldCenter Location

- Indicate centre for mould productionInclude this clause as compulsory upon mould

approval

Page

31

Add Mould ProtectionLegs

- When loading mould, add legs for mould oilpressure core, coolant hose production and toreplace wooden plates

Page

16,28

Standardize Eye-Bolt

- Standardize Eye-bolt joining parts and Eye-

bolt color according to mould size

Page

59

Oth.Equip.

Install Pre-Heater- While model change, install pre-heater to

shorten mould temperature increasing waiting timePage

12

One TouchSystemization forHose Joint Area

- Create One Touch systemization to shortentime when separating and connecting coolant

Page

32,37

Prepare Valve GateHeater

- Install heaters in previous injection machinesusing valve gate to remove waiting time

Page

12

Standardize ToolCart

- During model change, create and utilizecompulsory tool carts

Page

14

Oth.

Standardize

Cyclinder RetreatLocation

- Standardize injection machine nozzle retreatdistance according to injection machine capacity Page19,40

Indicate Hoist StopLocation

- To reduce adjusting time of injection machineand mould centre, indicate arrows along hoistmoving rail

Page

17,30

Install Hoist Hook- For easy tightening of mould and hoist, stick

hook on rope connected to hoistPage

10,16,35

Appoint MouldWaiting Area besideMachine

- Appoint waiting area for before and after modelchange (nearby injection machine)

Page

16

PeopleOperate Model ChangePIC

- Ensure model change work professionalism byappointing model change Person-In-Charge

4



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P/L

910

1

2

15

3

4

5

6

7

8

11

12 13 14

16

No. Name No. Name

1 Fixed Install Plate 9 Locate Ring

2 Fixed Plate 10 Sprue Bush

3 Moving Plate 11 Guide Pin4 Spacer Block 12 Ejector Sleeve

5 Upper Ejector Plate 13 Core Pin

6 Lower Ejector Plate 14 Ejector Pin

7 Moving Install Plate 15 Angler Pin

8 Core 16 Side Core

5



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This manual is based on 850T Valve Gate Injection Machine

Parts Details

BedBase for installing form, injection. oil pressure,

electronic equipment

Form

Equipment

Equipment which closes mould so that mould doesn't open

- Fixed part, moving part, tie bar, form cylinder,

thickness adjusting equipment, Ejector, safety door

Injection

Equipment

Made up of hopper measuring materials and screw cylinder in

charge of injection

- Hopper : Storage apparatus used for storing material to

be supplied to screw cylinder

Oil Pressure

Control

Equipment

Oil Controlling part supplying operation rate

6



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Model Change WorkOrder

Model Change Standard Cycle Chart

. Detailed Model Change Work

Standard


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Work

Item

Work

OrderFactor Work

Time(s) Time Cycle Chart Ref.

(before)A B 1min 2min 3min 4min 5min 6min 7min 8min 9min 10min

Ou

ter-

Preparation

01 Obtain Production Plan for Day 30 mins

02 Create Model Change Chart 300 20 mins

03 Move to Mould Storage Area 30

90 mins04 Find Mould, Connect Hook 30

05 Move to Pre-Heat Waiting Area 120

06 Connect Mould to Pre-Heater 6060 mins

07 Set Temperature, Check for Leak 30

08 On Heater, Set Temperature 40 20 mins

09 Prepare Tools 3010 mins

10 Move to Facility Area 60

11 Move Hoist to Pre-Heating Mould 60

10mins

12 Separate Pre-Heater from Mould 10

13 Separate Heater 10

14 Connect Finished Mould to Hoist 10

15Move to Model Change Injection

Machine300

16Separate Finished Mould from

Hoist10

17 Move Hoist to Upper Injection

Machine30

18 Block Coolant IN/OUT Valve 5

19 Open AIR OUT Valve 5

20 Insert AIR to remove remainder 60

In

ner-

Preparation

01 Stop Injection Machine

02 Off Heater Power 2

03 Retreat Injection Machine Nozzle 2

04 Open Front Safety Door 5

05 Apply Grease on Mould 15

06 Open back safety door 5

07 Separate Fixed Coolant Hose 10

08 Separate Moving Coolant Hose 10

09 Check Mould Interior 5

10 Close Mould 5

11 Lower Hoist 20

12 Separate Heater Connector 10

13 Separate AIR Hose 10

14 Separate Timer Wire 10

15 Connect Hoist to Eye-Bolt 15

16 Connect Final Hoist 5

7



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Work

Item

Work

OrderWork Factor

Time(s) Time Cycle ChartRef.

A B 1min 2min 3min 4min 5min 6min 7min 8min 9min 10min

Inner-

Prepara

tion

17 Release Clamp Pressure 10

18 Separate Gasket 10

19 Separate Clamp 10

20 PIC B Separate Clamp 10

21 Open Moving Plate 10

22 Separate Previous Mould fromInjection Machine 5

23 Move and Lower 50

24 Check Injection Condition 30

25 Set Conditions 5

26 Check Conditions 25

27 Separate Finish Mould From Hoist 15

28 Connect Model Change Mould to Hoist 15

29 Move Mould 20

30 Lower Model Change Mould toInjection Machine 30

31 Adjust Locate Ring 30

32 Adjust Nozzle Center 15

33 Prepare Gas Supply 30

34 Prepare Heater Supply 30

35 Add Clamp 10

36 Tighten clamp 10

37 Connect Fixed Part Coolant Hose 15

38 Connect Moving Part Coolant Hose 15

39 Lower Hoist 10

40 Separate Hook 15

41 Move Hoist 20

42 Adjust Mould Thickness 20

43 Open Mould 5

44 Connect Heater Wire 10

45 Connect Air Hose 10

46 Connect Timer Wire 10

47 Open Front Safety Door 5

48 Clean Grease Inside Mould 30

49 Set Coolant Conditions 10

50 Set Heater Conditions 10

51 Set Gas Conditions 10

52 Forward Injection Cylinder 12

53 Squeeze Resin 30

54 Change Machine to Semi-Auto 5

55 Set Detailed Injection Conditions 5

56 Product Out and Check 120

57 Record Model Change Time

Oute

r-

Prepar

01Move Mould Beside Injection Machine to

Mould Storage300

02Indicate Complete on Model

Change Chart20

03 Arrange Model Change Carts 60

Time depends on product's cycle time : Based on Cycle Time of 60s second product

8



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(1) Obtain Production Plan of the day

A. Get production plan from the supervisor : 30 minutes before work

(2) Create current model change plate

A. Record as "Model Change Chart" in the production plan:

20 minutes before work

(1) Record pre-heating time and ensure pre-heating time doesn't overlap.

Oth.Prep -01 Create Current Model Change Chart PIC A

2. Create Model

Change Chart

1. Obtain Production

Plan of the day

NOEquip.

Name

Model

Mat. Col.

Model

Change

Expected

Time

Mould

Temp.

H/R

Temp

Pre-Heat

PICBefore AFter

Start

Time

End

Time

1 850MG 34D20 34D11 HF1690 11:40 50C 220C 10:50 11:30 Hong

9



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(1) Move to Mould Storage Area : 90 minutes before

A. Adjust according to model change plan and move to mould storage area

(2) Find Mould, Connect Hook

A. In the mould storage, look at mould storage

and confirm mould location.

B. Lower the hoist pulled and connect the hook

of the hoist to the mould's .

(3) Move to Pre-Heat Waiting Area

A. Pull up the hoist and move the mould to Pre-

Heat waiting area.

While using movable pre-heat equipment, move mould

near to assigned mould change injection machine

B. After lowering the mould at the Pre-Heat Waiting area, separate the hook

C. Stick the pre-heat waiting number on the mould according to order.

(1) Assign Address to mould storage so that it would be easy to locate them

(2) For fixed type pre-heater, place it at a maximum distance from the

mould storage

(3) Mould Storage must concur with the current sheet and the mould

(1) Indicate Location in Mould Storage & Operate Location Sheet

Setting (Appoint Address)

Move Mould to Mould Pre-Heat Area PIC A

2. Find Mould,

Connect Hook

3. Move to Pre-Heat

Waiting Area

1. Move to Mould

Storage

Eye-Bolt&Hook

Mould Storage Location Sheet

Oth.Prep -01


10


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Code NO.Product

Name

Injection

MachineRef.

Length Width No.

50L3 F/C 1,300TON

32Z10 B 3 B3 B/C 850TON11


Place

Indication

Address Address

Number

Equipment

Number

Number

Color

Arrangement

Main Passage

Sub-

Pass

age

11


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(1) Connect Pre-Heater : (Pre-Heat time + 10mins)before

A. According to order of model change chart, move the model change mould

to the pre-heater location.

Pre-Heat time could vary greatly due to Pre-Heater's amount and

mould size

B. Connect Pre-Heater's IN line connector to mould's coolant block IN line

C. Connect Pre-Heater's OUT line connector to mould's coolant block OUT line

D. Open the temperature adjusting valve starting from the OUT line, then open the

temperature adjusting valve of IN line

(2) Set temperature, Check for leaks

A. On the power of pre-heater

B. Check if pre-heater is functioning

C. Set the pre-heater's water temperature as +% of the

mould temperature according to the respective mould's

condition chart and check for circulation

D. Check for leaks on mould and block

(3) Connect heater, set temperature

A. Connect the valve gate wire connector to the mould's

connector, adjust the left and right

B. On the valve gate heater power

C. Set the valve gate heater's temperature

Oth. Prep - 03 Connect Pre-Heat Hose to Model Change Mould PIC B

3. Connect heater,

set temperature

2. Set temperature,

check for leaks

1. Connect mould to

pre-heater

12


Pre-Heater

Heater Controller


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(1) Check water circulation of mould with eyes : water drop's flow

(2) Set pre-heater water temperature : +% of product's condition chart

(3) Check for errors on valve gate temperature (Set temp to current temp)

- Heater controller temperature standard should be about 90% of the

melting temperature of resin being used

(4) Checking for achieving mould temperature can be done by adding the

magnetic temperature on the mould chart to see if set temperature and

surface temperature concur

(1) Standardize cooling hose IN/OUT joint point color

Ex) IN(Blue), OUT(Red)

(2) Establish mould pre-heating system

(3) Stick mould coolant block

Standardize color code

Stick cooling block

13



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(1) Tool Cart Preparation : 10 minutes before

A. Move to and search for the tool cart

(2) Move to facility area

A. With the tool cart, return to injection facility and store at site

(1) Make sure there are no tools missing needed at model change

(2) Check the availability of grease and others

(1) While using tool cart, minimize borrowing of tools

from moving and narrow area to longest distance

- Tools needed : 'L' wrench SET, spanner, hammer

coolant nipple, grease, etc.

(2) Minimize model change tools by reducing the

number of tools by apply One Touch System and

others at the connecting areas

04 Prepare Model Change Tools PIC A

2. Move to Site Area1. Prepare Tool Cart

14



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(1) Move hoist to pre-heating mould : 10 minutes before

A. Move to the pre-heating mould of the pre-heating area

(2) Separate pre-heater from mould

A. Before separating pre-heater, check using magnetic temperature if the

Pre-Heater equipped with pre-heat completion lamp, check the pre-

heat completion lamp

B. Off the Pre-heater power

C. Block the IN, OUT valve connected to the pre-heater and mould to blockthe coolant supply

D. Remove remaining coolant

E. Pull the hose fix lever at the left, right side of cooling hose end,

separate the 2 hose from the mould and hook it to the pre-heater hook

(3) Separate heater

A. Off the heater controller's power

B. Pull back the fix lever at the end of left, right side

of the heater wire connected to the upper mould,

arrange the wire after separating connector

(1) Prepare a hook to arrange the hose or wire

Oth. Prep- 05 Separate Mould from Pre-Heater PIC B

3. Separate heater2. Separate mould

from pre-heater

1. Move hoist to pre-

heating mould

15



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(1) Connect Pre-Heated Mould to Hoist : 10 minutes before

A. Lower hoist using hoist adjuster

B. Connect mould's Eye-Bolt using hoist hook

(2) Move to Model Change Injection Machine

A. Move the mould connected to the hoist by using

to model change injection machine

B. Lower mould at assigned area near injection

machine

Connect Hook

(1) Check if mould waiting place has been assigned near injection machine

(1) While adding legs to lower mould, it will save

time when lowering the mould

- Prevent lower mould oil pressure core, slide

core, coolant fitting damage

2) Mould lowering place must be indicated on the

moving rails of the hoise to reduce moving time- Mould waiting area must be assigned

Oth.Prep -06 Move Pre- eated Mould to Injection Machine PIC B

2. Move to Mould Change

Injection Machine1. Connect Pre-Heated Mould to Hoist

Add legs

Assign mould

waiting area

16



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(1) Separate Pre-Heated mould from hoist : 5 minutes before

A. Separate hook of pre-heated mould moved to nearby injection machine

(2) Move the Hoist to Upper Injection Machine

A. Move hoist using the hoist's wire lever button

B. Adjust the injection machine and hoist center in a line

C. Move the hoist wire to near the injection machine control panel,

quickly locate it to the place of model change

(1) Adjust the arrows along the hoist moving rail to the arrows indicated

on the walls of lower rail and adjust the hoist to the center of

injection machine

(1) Before mould change, adjust the hoist to center

of the injection machine and prepare moving time

(2) To reduce center adjust time, apply a sensor to

hoist moving location to auto-stop

Oth.Prep -07 Move Hoist to Upper Injection Machine PIC B

2. Move Hoist to Upper Injection

Machine

1. Separate Pre-Heated Mould from

the hoist


Adjust Hoist Center

17


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(1) Block Coolant IN/OUT Valve : 3 minutes before

A. After moving hoist, move behind injection machine

B. Block coolant supplier IN/OUT line's fixed

and moving side's belt

(2) Open AIR OUT Valve

A. Open Air valve connected to the coolant supply

equipment OUT line

(3) Inject AIR and remove residue

A. Open Main Air connected to IN line, and when air is

supplied into mould and water exits, wait for 1~2

minutes and check with eyes

B. Set the coolant supplier temperature according to the

facility chart of appropirate pre-heat conditions of

the model change mould

(1) Check for any decreasing pressure of pressure gauge installed in the mould's

residue removal system and check for remaining substances being removed

(2) Standardize coolant hose IN/OUT joint areas

Ex) IN(Blue), OUT(Red)

OUT

Oth.Prep- 08 Remove remaining coolant in current mould PIC B

1. Block coolant

In/Out Vavle2. Open Air Out

Valve3. Inject Air to Remove

Residue

IN

18

Block IN Valve

Block OUT Valve


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(1) Stop Machine : Start Model Change

A. When last injection is complete, mould opens and product ejected,

change injection machine to manual and stop the injection machine

(2) OFF Heater Power : 2 seconds

A. Press Off button on heater controller and off

(3) Retreat Nozzle : 2 seconds

A. Use nozzle retreat lever on control panel and

(1) Add Timer on injection machine and time Model change from the beginning

(1) Standardize nozzle retreat according to

injection machine's amount

(Reference : Vacuum Cleaner 200mm, VD 300mm)

In.Prep-01 Stop Injection Machine and Retreat Nozzle PIC A

3. Retreat Injection

Machine Nozzle2. OFF Heater Power

1. Stop Injection

Machine

19



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(1) Open Front Safety Door : 5 seconds

A. With current mould OPEN, open the front safety door

(2) Apply Grease on Mould : 15 seconds

A. Apply appropriate amount of grease on completed mould surface with

20cm gap from the fixed side's mould

B. When fixed side is completed, apply using same method on moving side

(1) Greased should be equally spread on the mould

surface by shaking UpDown, DownUp

(2) For long-term storage with moulds rusted or core,

apply ample amount to prevent rust

(1) Spread evenly to prevent mould's rust

In. Prep - 02 Apply Grease on Mould PIC A

2. Apply Grease on

Mould

1. Open Front Safety

Door

20

Grease Applyinbg Order

Apply Grease


29/78


(1) Open Back Safety Door : 5 seconds

A. PIC A waits behind model change injection machine till stop

B. When injection machine stops, open back safety door

(2) Separate Fixed Side Cooling Hose : 10 seconds

A. Holding end of fixed side mould IN line hose,

pull the fixed lever and unlock

B. After unlocking,pull the hose with both hands

and separate the mould

C. Same steps as 1), 2) is applied to fixed side OUT line hose

(3) Unlock moving side coolant hose : 10 seconds

A. Same above steps are applied for moving mould IN,OUT line

(1) The separated cooling hose should be placed

where it won't be disturbed during moving of

the mould

- Use cooling hose hook

In.Prep - 03 Separate Cooling Hose from Mould PIC B

3. Separate Moving

Side Cooling Hose

2. Separate Fixed

Side Cooling Hose

1. Open Back Safety

Door

21


Separate Cooling Hose

Arrange Cooling Hose


30/78


22



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(1) Check Inside Mould : 5 seconds

A. After applying grease, do a final check inside

the mould

B. After checking for mould errors, close safety

door of the injection machine

(2) Close Mould : 5 seconds

A. At the control panel, turn the mould close switch left slowly and

close the moving mould manually

(3) Lower the Hoist : 20 seconds

A. After closing mould, press hoist adjustor lower button to lower hoist

(1) Before closing mould, PIC B must disconnect coolant and check

if it has been moved to a safety area

In.Prep - 04 Close Mould and Lower Hoist PIC A

3. Lower Hoist2. Close Mould1. Check Inner Mould

23


Check Inside Mould


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(1) Disconnect Heater Connect : 10 seconds

A. After disconnecting coolant, go up injection

machine and wait till mould close

B. Pull out connector by pushing heater connector

fix lever on upper mould left and right

(2) Disconnect Air Hose : 10 seconds

A. Disconnect Air hose with same method above

(3) Disconnect Timer wire : 10 seconds

(In case of a successful mould)

A. Disconnect Timer wire with same method above

1) Disconnected surrounding connectors should be arranged and hung on hook

so not to disturb lowering of mould

1) Standardized heater connectors PIN numbers to

improvement replacement time during model change

(Vacuum Cleaner : Standardize to 16PIN)

In.Prep - 05 Disconnect Heater, Timer, Air Hose PIC B

3. Disconnect Timer2. Disconnect Air Hose1. Disconnect Heater

, AIR

Standardized to 16 PINS

24


Disconnect Connector

Disconnect Timer, Air Hose


33/78


(1) Connect Eye-Bolt and Hoist(PIC B) : 15 seconds

A. Lower the hook on manila rope to a position

possible to connect to a completed mould's

Eye-Bolt

B. After connecting hook to mould's Eye-bolt, send completion signal to

PIC A

(2) Hoist Final Connection(PIC A) : 5 seconds

A. PIC A must slowly press the upper button on the hoist adjustor until

the hoist line becomes tight, then lift it up to check the connection

for the final time

1) Before connecting hook, turn the Eye-Bolt connected

to the mould, and check if it's been connected fully

1) Reduce connecting time by using hook on manila rope

2)

In.Prep - 06 Connect Mould's Eye-Bolt and Hoist PIC A, B

2. Hoist Final

Connection

1. Connect Eye-Bolt and

Hoist

Eye-blot&

25


Connect Eye-Bolt & Hook

Center

Moving

Plate

Fixed

Plate


34/78


(1) Release Clamp Pressure : 10 seconds

A. Ensure hoist is tight, and prepare for Auto Clamp separation

B. Change Clamp Adjustor lever to 'Change'

(2) Separate Gasket : 10 seconds (Apply when gas)

A. While clamp pressure is reducing, separate

gasket inside the mould

(3) Separate Clamp : 10 seconds

A. After checking Auto clamp pressure has reduced,

send separation signal to PIC B

B. Pull 2 clamps on fixed side and separate

C. Pull 2 clamps on moving side and separate

(1) Check if Auto clamp's pressure gauge is '0'

In.Prep - 07 Separate Auto Clamp(QMC) PIC A

3. Separate Clamp2. Separate Gasket1. Release

Clamp Pressure

QMC : Quick Mold Chager AUTO

26


Separate Gasket

Separate Clamp

Check Pressure Gauge

Apply AUTO Clamp


35/78


(1) Separate PIC B Clamp : 10 seconds

A. After separating upper mould's injection surrounding components,

climb down behind injection machine and wait

B. After receiving separation signal from PIC A,

prepare for oil pressure clamp separation

C. Pull 2 clamps on fixed side and separate

D. Pull 2 clamps on moving side and separate

(1) After completely separating the clamp, inform completion to PIC A

In.Prep - 08 Separate PIC B Clamp PIC B

1. Separate PIC B Clamp

AUTO

AUTO

27


Separate Auto Clamp

Apply AUTO Clamp


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(1) OPEN Moving Plate : 10 seconds

A. After checking separation completed signal from PIC B, using injection

control panel's clamping switch and open manually

(2) Separate completed mould from injection machine : 5 seconds

A. Check if mould's is ejected from injection machine

B. Raise the mould on hoist vertically and eject from injection machine

(3) Move and Lower : 50 seconds

A. Move completed mould to the beside injection machine

(1) While separating mould, ensure locate ring is not damaged by hitting

the injection machine

(2) Move completed mould to model change mould and reduce time by using

hoist

(1) Add legs on mould to improve support work while

lowering

(2) Assign a place to lower mould and must indicatesection

In.Prep - 09 Separate Completed Mould and Move PIC A

3. Move and Lower

2. Separate completed

mould from

injection machine

1. OPEN Moving Plate

28


Add Mould Legs


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(1) Search Injection Conditions : 30 seconds

A. Take out Auto Clamp and move it in front of the injection machine

B. Press the memory button on injection machine's control panel, and

search for the model change mould's name using the up-down button

(2) Recall Conditions : 5 seconds

A. Check the model name and select "Recall"

(3) Check Conditions : 25 seconds

A. After Recall of injection conditions of the appropriate model, check

for any errors

1) Maintain and manage that the mould's injection

condition data file in possession are saved in

the injection machine.

In.Prep - 10 Recall Injection Conditions PIC B

3. Check Conditions2. Recall Conditions1. Search Injection

Conditions

29


Recall Injection Conditions


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(1) Separate Production Completed Mould from Hoist : 15 seconds

A. After lowering completed mould, separate hook connected to Eye-Bolt

B. Move hoist to model change mould

(2) Connect Model Change Mould to Hoist : 15 seconds

A. Connect model change mould's Eye-Bolt to hook connected to hoist

(3) Move Mould : 20 seconds

A. Lift model change mould and move to injection machine

B. Match arrows indicated on the hoist moving rail to the arrows

indicated on the crane

(1) Turn model change mould's Eye-Bolt and check if it's completed

connected

(1) Indicated stop sign on hoist and crane to

reduce hoist moving time.

In.Prep - 11 Move Model Change Mould PIC A

2. Connect Model

Change Mould to Hoist3. Move Mould

1. Separate Completed

Mould from Hoist


Adjust Hoist Center

30


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(1) Lower Model Change Mould to Injection Machine : 30 seconds

A. Adjust model change to lower.

B. Using mould "Close" lever on injection machine's control panel, close

moving plate to mould moving side to about 30cm and push the mould to

fixed side

(2) Adjust Locate Ring : 30 seconds

A. Adjust hoist minutely and move locate ring close to injection machine

B. Using hoist adjustor's left-right button to adjust hanging mould's parallel

(3) Adjust nozzle center : 15 seconds

A. Adjust the mould's locate ring with the nozzle center

(1) Adjust mould and injection machine's center line.

(2) Check in advance the locate ring's damage on mould to

prevent problems after model change.

(1) Make a locate ring guide hole on injection machine's

fixed plate to reduce mould lowering time.

(2) Adjust locate ring's height and manufacture Taper's end

to allow easy fitting.Taper

In.Prep - 12Fix Model Change Mould to Injection

MachinePIC A

2. Adjust Locate

Ring

1. Lower Model

Change Mould to

Injection Machine

3. Adjust Nozzle

Centre

Indiciate Mould and

Injection Machine's Center


Make Taper

31


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(1) Prepare Gas Supply (Based on Gas Using Model) : 30 seconds

A. Insert gas conditions of model change mould into gas supplier

(2) Prepare Heater Supply : 30 seconds

A. Check for any errors on heater wire

B. Check for errors on each heater controller's functions

C. Check if heater temperature matches the model change mould temperature

and adjust

(1) After checking for any errors on heater controller, if there is,

replace the controller.

(1) Change gasket connection parts to One-Touch

Connection method.

(2) Standardize connector Pin Type of Heater

Controller

In.Prep- 13 Prepare Gas, Heater Supply PIC B

2. Prepare Heater Supply1. Prepare Gas Supply

One Touch


One Touch Gasket Connection

System

32


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(1) Connect Moving Side Cooling Hose : 15 seconds

A. After clamp connection is completed, insert fixed side's coolant hose

IN line connector to fixed side's mould coolant block blue connector

B. Tighten fixed lever at end of both temperature controller connector

and connect

C. Insert fixed side's coolant hose OUT line connector to fixed side

mould coolant block red connector, tighten fixed lever and connect

(2) Connect Moving Side Coolant Hose : 15 seconds

A. Apply the same method above for moving side's coolant hose

(1) Check hose's connectivity on coolant block and hose connected to mould

(2) Check if the connectivity is according to IN, OUT color

In.Prep - 15 Connect Cooling Hose PIC B

2. Connect Moving

Side Cooling Hose

1. Connect Fixed Side

Cooling Hose


Add Coolant Block

34


43/78


(1) Lower Hoist : 10 second

A. After PIC A checks clamp connection, using hoist's controller, lower

the tight rope until above mould and loosen.

B. At this point, after PIC B connects clamp, go up the mould in advance

and wait

(2) Separate Hook : 15 seconds

A. When rope loosens, after separating mould, send signal to PIC A.

(3) Transfer Hoist : 20 seconds

A. After PIC A checks that hook is separated, move hoist to completed

mould location.

(1) Before separating hook, pull oil pressure clamp and check if properly

connected

(2) After PIC A checks that hook is completely separated, move the hoist

(1) After changing end of manila rope to hook, rope

connection and separation time will be reduced.

In.Prep - 16 Separate mould hoist within equpment PIC A, B

3. Transfer Hoist2. Separate Hook1. Lower Hoist

35



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(1) Adjust Mould Thickness : 20 seconds

A. After moving hoist, switch "Mold Set" to On on injection machine's

control panel.

B. Find on control panel and On.

C. Look at mould thickness adjustment completion indication lamp and

check

(2) Open Mould : 5 seconds

A. After mould thickness adjustment completion, open mould

1) After adjusting thickness and mould opens, press the Eject button and

check the movement conditions of the Ejector Pin

1) If the location of Ejector pin and size is

standardized, Ejector Pin Replacing time

could be Zero

In.Prep - 17 Adjust Mould Thickness PIC A

2. Open Mould1. Adjust Mould

Thickness

Ejector


Standardize Ejector Pin

36


45/78


(1) Connect Heater Wire : 10 seconds

A. Once mould is fixed into equipment, go up injection machine and insert

mould's connector according to heater wire's left, right channel

B. After connecting the connector, pull the fixed equipment found on

mould connector's left, right inwards, and fix the inserted wires.

(2) Connect Air Hose : 10 seconds

A. Hold the Air supply hose, push and fit the air hose insert nipple

found on mould

(3) Connect Timer Wire (Sequence Injection) : 10 secs

A. Insert and fix the timer connector wire

using the same application as heater wire

B. After connecting injection surrounding

components, come down from the machine

(1) Change Air hose connection parts to One Touch

method to reduce time One touch

-18 Connect Heater, Air Host, Timer Wires PIC B

3. Connect Timer Wire2. Connect Air Hose1. Connect Heater Wire


Improve One Touch

37


46/78


(1) Open Front Safety Door : 5 seconds

A. When mould moving plate opens, open the front safety door

(2) Clean Grease Inside the Mould : 30 seconds

A. Prepare cleaning tool(hand rug), go inside the mould, then clean the

grease applied on surface of mould's fixed side using up, down strokes

B. Clean the grease applied on mould's moving side using up, down strokes

(1) Grease is left on mould's bottom edges so pay attention.

- If grease is not removed, it will stick onto product during

production

(1) If glove-type hand rug is used to fix hand in,

cleaning time can be reduced.

(2) If a thin sponge can be added inside on the

cleaning part, it would be useful for cleaning

In.Prep - 19 Clean Grease PIC A

2. Clean Grease Inside

the Mould

1. Open Front Safety

Door

38



47/78


(1) Set Coolant Conditions : 10 seconds

A. Move to injection machine's coolant controller, open IN line valve

B. Open the coolant controller's OUT line too, and press the "DRIVE"

switch on temperature controller to function.

C. Press on each "Water Maintenance" switch, "Cold Water", "Heater"

switch to function

D. Check if each lamp is functioning normally, and match temperature

(2) Set Heater Conditions : 10 seconds

A. Switch ON the heater controller power and press the power switch on

each cell to switch ON

B. Set if temperature setting on thermometer's each cell indicating

screen is set according to surrounding component's condition chart

(3) Set Gas Conditions : 10 seconds (For Gas Usage)

A. Recall gas equipment's injection conditions, and check each stage's

pressure and time, then maintain the equipment at manual

(1) Standardize of surrounding components per

injection machine, such as the chart on right.

In.Prep - 20 Set Coolant, Heater, Gas Conditions PIC B

3. Set Gas

Conditions

2. Set Heater

Conditions

1. Set Coolant

Conditions

[ ]

39


[Standardize Chart per Machine]


48/78


(1) Forward Injection Cylinder : 12 seconds

A. After cleaning the grease, use the Transfer Level of the control panel

to forward the retreated injection cylinder, nozzle close to the mould

(2) Squeeze Resin : 30 seconds

A. Use injection measuring lever of control panel to squeeze the

overheated Resin in mould's valve gate from previous LOT production

and in the nozzle

B. Open injection machine's safety door, go inside, remove the squeezed

Resin to make the mould surface clean

(3) Switch Injection Machine to Semi-Auto : 5 seconds

A. Come out of the injection machine, close the safety door, and move the

operator lever on control panel to semi-auto location

(1) Ensure that the squeeze resin does not remain on mould surface.

(1) Indicate location to reduce cylinder forward

and retreating time

In.Prep - 21 Squeeze RESIN PIC A

3. Switch Injection

Machine to Semi-Auto2. Squeeze Resin

1. Forward injection

Cylinder


Set Cylinder Retreat

Location

40


49/78


(1) Adjust Detailed Injection Conditions : 5 seconds

A. Close MouldInject Cooling(Amount)Check the production in progress,

move to injection machine's control panel, and adjust detailed

injection conditions (temperature, pressure)

(2) Eject Product and Inspect : 120 seconds

A. When product is ejected after production is complete, inspector

waiting judges pass or reject according to the product standards

B. Proceed if product passes, re-inject again if rejected, then inspect

and check until product passes

120 seconds based on 2 products whose Cycle Time is 60 seconds

(3) Record Model Change Time

A. If product passes, record the model change time, and proceed

1) Execute sample inspecting according to Inspection Standards.

- Using assigned tools, inspect measurement per Inspection Point, formation.

2) Prepare acceptable limit sample, and compare with first product.

1) Inform model change on day schedule to inspection department in charge to prevent

problems on inspection manpower, limit sample, and ensuring Inspection Standards

In.Prep - 22 Sample Injection PIC A

3. Record Model

Change Time

2. Eject Product and

Injection

1. Adjust Detailed

Injection Conditions


41


50/78


(1) Transfer Mould beside Injection Machine to Mould Storage Area

A. Connect hoist to model change completed mould and transfer to mould

storage area.

B. After checking Mould Storage Location, return to its position.

(2) Indicated Completion on Model Change Start

A. Indicate Model Change on Model Change Chart to mark model change

completion and check the next model change.

(3) Arrange Model Change Cart

A. Transfer model change cart to the waiting area.

1) Make sure to store mould according to the location shown on the mould

location chart.

In.Prep - 08 Arrange After Model Change

3. Arrange Model

Change Cart

2. Indicate Completion

on Model Change

Chart

1. Move Mould beside

Injection Machine

to Mould Storage

PIC A, B


42


51/78


52/78


/

(, , )

,

(VTR),

LCA, , JIG

43

Inspect Model Change Actual, Categorize Model

Change Waste Inspect Site(VTR Record), Model Change Analysis

Chart

Divide to clauses possible to change oth.

preparation during Model Change Work

Improve In./Oth.Preparation Work's Waste

(Preparation, Replacement, Adjustment, etc.)

Preparation systemization of In. Preparation Work

Execute manual work of LCA, Automation, JIG, etc



53/78


1) Whichever that can be prepared in advance should be prepared

(1) In.Preparation Work to be prepared before model change

2) Hands can be moved, but not feet

(1) Preparation work consists of searching, selecting,

transportation work.

(2) During model change, it is important not to make more than

3 footsteps.

3) Improvements for Preparation Waste removal

(1) Develop Exclusive Model Change Cart

(2) Manage Mould Location (Address Systemization)

(3) Set Model Change Order

(4) Make Model Change Check List

(5) Set Systemization of Model Change Tools

(6) Model Change Work Division according to Model Change Labor

(7) Create Work Order Chart and Standardize

(8) Arrange, Neat, Properly, Clean(9) Account for the Number of Tools

(10) Adopt Utilization, Scale, and Dial

(11) Assign Mould and Tools Near To Equipment

(12) Methods to Place Beside for Mould Transportation

(13) Clean After Container is Cassette Systemized of Equipment

Functioned

44



54/78


Items Before Improvement After Improvement

Model

Change

Exclusive

Cart

Form and ToolsFindStart Looking

Transfer

Experiment with Excluse ModelChange Cart

Mould's

Address

System

Kit

System

Press's Mould Storage Location is

not clear, taking a long time to

search

Regards to Mould Storage, Address

System to indicate Address and

Number

Arranged per product, size and form. Kit system for Jig, Stick Section,

Gauge, Appropriate MeansuringSection per product

Form

Form

Form

Oil Grease

Plate's 7Types ofTools

Whereis it...

Addressrefers to agroup's roomnumber

Form Store

Tag

PunchStore

GlueToolStore

MeasuringInsp. Tools

ForProduct

A ForProduct

C

ForProduct

B

45



55/78



Model

Change

Order

Set Model Change Order.

Production

Plan

Product a

Worker Look at ProductionPlan and stick

model change card

Tech. Stick ManufactureDegree

Mould Lift Form

Sticking Section

Inspection Section

Check the site

Execute Model Change

ModelChangeWorker

After completing ~ , start backwards

While model change, record inconvenient Points

Refer to Clause A07 for model change tag

46

Empty Cart

Excluse Cart

Excluse Cart

Cart



56/78



C

h

e

c

k

L

i

s

t

Only after starting a model change,

tools not available were found.

Make a Check List of Model

Change.

Ex)

Model

Change

Tools

One thing noticed from the model

change was searching for tools for

model change and start looking.

Set up a system for model change

tools, then use when necessary

Items Types

Tools Spanner, Tighener ...

MeasuringTools Micrometer, Measuring Tool.

Oil Lubrication, Grease ...

Where'sthe cover?

I mustprepare a

Check List!

As they haveforms, it is easily

noticed whenmissing.

Spanner

Driver

Wrench

Hammer

When I needit...

47



57/78



1

Team

2Person

System

If one person works, he must work

in and around the facility causingunwanted waste while moving

Create a divided team with works

divided(Machine never stops.)

Model

Change

Order

Chart

Although model change worker was

assigned to tasks, worker had a lot

of waiting time. Model change is

not easy for a new work as it

requires adjustments, efforts and

experiences.

Create standard work chart, set an

order for worker's participation.

Model

Change

Zero

5

S

Stop the equipment and execute 5S. Before starting model change, after

preparation, begin cleaning after

functioning.

Model Change ChartProd.No.

Prod.Name

Time

NO Preparation Qty. Check Degree

12

345

a.b.

c.d.e.

Oth.1. Lift mould to cart and use bolt...2. 3.

Safety

first!

Assemble

the jig..

Neat

Arrange Clean

Order

48



58/78


1) Do not tighten or loosen bolts.

2) Completely remove the bolts.

(1) Function of bolt is to be used as deciding the tightening

and location of substitute area

3) The standard never changes.(Standard Principle of Fixture)

4) Improvements for Replacement Waste Removal

(1) Do not take out Bolt, tighten by turning once.

(2) Uniform height of tightening spots.

(3) Can be done with a small Nut and C-Type Washer.

(4) When Joint Torque is small, systemize Pin and Block.

(5) One Touch tightening using a handle type.

(6) Create a common system for each jigs.

(7) Do not move standards by space by Unit or by Work

(8) Use spring types rather than screws.

(9) Systemize One touch Cassette

(10) Minimize model change by with common jigs.

(11) Combine mould and jigs to reduce numbers.

49



59/78



Uniform

Joint

Height

Adjust jig's joining height to thesteel bracket, and tighten Bolt and

Nut. Do not use stand during

replacement.

Dependent Joint Area Do not take out the Nut.

Do not put in the stand.

Can tighten Nut with 1 turn.

Snow

-

Man

Type

Hole

C

Type

Washer

During form change, dismantle all

bolt, washer and jig.

Jig to be Snowman Type Hole,

do not take out the Bolt.

Small Type Bolt, Nut + C Type

Washer

P

i

n

B

l

o

c

k

Length is different per Work. When joint torque is small,

systemize Pin and Block.

(Sticking Pin and turning it is good

enough)

JIG

Spring Spring

BoltNut

Deciding location to be adjusted

with Bolt's measurements.

Pin

Pin Ball

50

Steel Bracket

Step

Type

StandStand

Washer



60/78


1) Do not move the base of manufacturing product

(1) Each time manufacturing standards differ as manufacturing products

change, do not change the base which is hard to change, change only

the ends which are easy to move

2) Systemize all adjusting work looking at scales as Block Gauge

3) Create Stopper and Guide

4) Improvements for Replacement Waste Removal

(1) Systemize Full Set as others model change.

(2) Do not take out the Set. Replacement only partial parts.

(3) Experiment common jigs.

(4) Systemize Block and Guide for mould's location decision.

(5) Standard decision should be a clash method.

(6) Use Block Gauge.

(7) Do not move the Limit Switch.

(8) Systemize set according to Standard Model.

51



61/78


Spacer

B

L

O

C

K


Spacer Joint Height can be uniform by using spacer

B

L

O

C

K

52

Uniform

Tighten

Height

Manufacturing Product Height different Uniform assembling height using spacer

Joint Height can be uniform by using spacerJoint Height can be uniform by

using spacer

Assembly Free

Set Tool

Bite Location

Decision

0 Setting

Measuring

Tool

Lengt

h

Model

Gauge

Locati

on

Decisi

on

Gauge

Bite

Model

Gauge

Bite Holder

Cassette Assembly Method: Model Change Time : 3 mins

Use Form Slide

and insert from

upper mould

Cassette Type

Slide

GAUGE

ST

OPPER

GUI

DE



62/78


63/78


Model Location Chart

Code NO.Product

Name

Injection

MachineRef.

Length Width No

50L3 F/C 1,300TON

32Z10 B 3 B3 B/C 850TON

54

Main Passage

S

ide

P

assage

Low

Usage

MOuld



64/78


To Measure Model Change Time of Assigned Equipment, and To

Analyze Current Standard

Model Change Actual Inspection Chart

Station 1 850 T A B 07 June A 52 mins

Station 2 1,300 T D E 08 June A 63 mins

Equipment Name : Each Injection Machine Station Number

(Ex : Station 2 etc)

Tonnes : Indicate Equipment Capacity

Before Model Change : Production Model Before Model Change

After Model Change : Production Model After Model Change

D A T E : Actual Model Change Date of Inspection Process

Worker : Actual Worker of Inspection Process Model Change

Time Consumed : Time Consumed From Production Model's

Production Completion Point to Next

Production Model's Production Point

55


65/78


Loss Rate based on Total Actual DATA Standard, Time

Consume/Time Production

Model Change Loss Time Chart

Station 2 2550 mins 450 mins 17.6 10 times 45.0 mins



Equipment Name : Record Detailed Work Process per Division

(Ex : PRESS Manufacturing, SMD PRINT etc)

Loading Time : Equipment and Manufacturing Operation Time

(Including Loss Time)

Model Change Time : Sum of Time incurred during Model Change

Model Change Loss Rate(%) : Sum/Loading Time of Model Change Time()

Number of Model Change : Number of Change Times Included in Model

Change TIme

Time Consumed/Times:Divide Model Change Time with No. of Times ()

After Collecting Actual Details Daily or Weekly, Create a Data System of

Actual Model Change Time per Number of Times Changed of each equipment.

56


66/78


There was no standard distance for cylinder's Forward/Retreat,

and during the process of distance checking by Person In Charge,

there was no location indication, resulting in excess moving

time than needed

Reduced moving time by standardizing cylinder's forward/retreat

distance. Maintenance by checking through stop location

indication

- Kwang Ju Vacuum Cleaner Example

Items

Retreat/ForwardDistrance (mm)

Retreat/ForwardTime (sec) Reduction

EffectBeforeImprove

AfterImprove

BeforeImprove

AfterImprove

Station 1 660 200 48 20 28

Station 2 480 200 78 35 43

Station 3 430 200 41 21 20

Station 4 660 200 48 20 28

Reduce Injection Cylinder's Forward/Retreat Time

200mm

57


67/78


Mould Pre-Heating done during In. Preparation, causing excess

Model Change Time

Oth. Preparation System by Applying Mould Pre-Heat System

Before Improvement After Improvement

Controller

Wait Time:General Mould 1,312 secs(VD)

H/R Mould 19 seconds

Wait Time for Temperature to

Rise After Placing Mould

Zero

Oth. Preparation To Reduce Mould Pre-Heat Time

General Mould Hot Runner Mould

Injection

Connect Controller

Place Mould

Pre-Heat Mould

58

Place Mould

Connect Controller

Waiting for Mould

Temperature to rise

Injection


68/78


- Eye-Bolt size differs according to mould weight so looking for

the correct Eye-Bolt size during Model Change wastes time

- Eye-Bolt process during In.Preparation waste time

- Standardize mould weight according to Eye-Bolt connection area

and Eye-Bolt color to improve preparation waste

- Preparation system for Others to improve waiting time waste

[Eye-Bolt Color Standardization]

[Eye-Bolt Oth.Preparation]

Eye-Bolt Preparation Time 35 secs 15 secs

(Color Standardization)

0 secs (Oth. Preparation)

Reduce Eye-Bolt Connect Time

59


69/78


Connecting each coolant hose, checking if In-Out has been

properly connected took excessive time

Reduce coolant connection time using a coolant block

- Color Division to prevent error in IN/OUT installation

- Apply One Touch Coupler to connect coolant block and

injection machine

Install Cooling Block

60


70/78


By using 24 Pin, 16 Pin based on Valve and Sensor quantity,

using 24 Pin caused connection preparation waste due to

additional wire connections

Simple work through standardizing Hot Runner Connection Jack

Standardization of Connection Jack through Mould's Valve and

Sensor Quantity Standardization

Standardize Hot Runner Connection Jack

16 PIN24 PIN

16 PIN

61


71/78


Due to low protruding height, it was easy to fall off even if it

was centered, and can only connect when accurately adjusted

Through standardizing appropriate height setting for height

difference per mould to reduce Location Ring Center Adjusting

Time

Standardize Locate Ring

Taper

20mm

62

Height 20mm

Manufacture Taper

for Form Stick


72/78


After connecting Manila Roipe to Eye-Bolt, connect to Hoist hook

Add another Hook on Manila rope to reduce Eye-Bolt and rope

connecting time

Improve Hoist Wire Connection Method

63


73/78


While transferring mould by crane, adjusting injection equipment

center wastest time

With mould center location indication per equipment, reduce

hoist location adjusting time

During model change per equipment, differentiate previous and

next mould lowering area with different color for possible

additional transfer time reduction

Install Crane Location Adjusting Indicator

During Model Change,

indicate previous and next

mould lowering area as

per and

64


74/78


Lots of waste factors during surrounding component dismantling

such as Gas, Air, Oil Pressure Hose, Coolant Connection Area etc

Various hose spread over the surrounding floor during model change

Gas Connection and Fitting Situation

Reduce dismantling time by applying One Touch Connecting areas

Providing exclusive holder for various hoses.

Reduce Surrounding Component Dismantling Time

65


75/78


While loading mould, locate ring center adjusting process causes

Work Loss

Find the center of Fixed Plate and make a channel to allow easy

locate ring center adjustment during model change

Reduce Locate Ring Center Adjusting Time

66


76/78


During the process of using wooden plates to place the mould on

the floor, it consumed a lot of time

Adding mould protection legs reduced time, allowing fast mould

lowering onto the floor

Add Mould Protection Legs

67


77/78


Ejector Hole's location and size differed per moulds, resulting

in changing the location of the Ejector Pin while replacing

mould

Erased replacing Ejector pin location work while replacing mould

by standardizing the size and location of mould's Ejector Hole

Standardize Ejector Hole Location and Size

68


78/78


During the process of lowering mould into facility, adjusting

locate ring center in detail caused adjusting waste

Create a locate ring guide line on injection machine's fixed

plate

Improve Location Ring Center Adjusting