Injection Molding
Industry:
Injection Molding
Mission:
Reduce Cost, Increase profitability
Challenge:
- Reduce Energy Cost
- As an example,
- - 2000 Ton IMM
- - Operating 3 shifts, 250 days a year
- - Power usage: 400 KW/h at 0.10 $/KWh
- - Cycle Time = 60 Sec
- - 3 Setups per day @40 minutes each
- - Cost of electricity = $220,000
- As an example,
- Reduce Energy Cost
Solution:
- Energy Value Stream Mapping (EVSM)
- In the above example,
- - After the change over time is reduced to 25 minutes through SMED
- - After the cycle time is reduced to 50 seconds through Standardization and implementing ideas such as:
- Reduce the mold open distance
- Close on the fly
- Reprogram the robot
- - Then cost of electricity = $180,000
- Energy Value Stream Mapping (EVSM)
Result: $40,000 annual savings in energy usage for one machine