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

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

Result: $40,000 annual savings in energy usage for one machine