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Redefining Mold Maintenance. Maintenance…The Final Frontier Globalization now requires more than ever, your expensive fleet of molds to be production.

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Presentation on theme: "Redefining Mold Maintenance. Maintenance…The Final Frontier Globalization now requires more than ever, your expensive fleet of molds to be production."— Presentation transcript:

1 Redefining Mold Maintenance

2 Maintenance…The Final Frontier Globalization now requires more than ever, your expensive fleet of molds to be production ready and process reliable. Companies steeped in a reactive, firefighting culture are upgrading inefficient practices to meet the challenges of today’s market. The disorganized approach of hand writing notes in log books and random instructions in typical work order formats is disappearing. The bar… and the stakes… have been raised, while resources, budgets and inventory…are continuously lowered. The bar… and the stakes… have been raised, while resources, budgets and inventory…are continuously lowered. The key to improving mold performance and maintenance efficiency lies in the ability to identify and understand the issues, standardize maintenance practices and to fully utilize the data that you spend time collecting. MoldTrax 4.0 was born for this.

3 Typical Maintenance Culture Firefighting the hot issues…over and over Firefighting the hot issues…over and over Freelancing repairs…no shop consistency or standardization…everyone doing their own thing Freelancing repairs…no shop consistency or standardization…everyone doing their own thing Documentation practices…”journal” type W/O records with no structure and of little value Documentation practices…”journal” type W/O records with no structure and of little value Little communication with outside vendors concerning mold requirements or maintenance practices. Little communication with outside vendors concerning mold requirements or maintenance practices.

4 Types of Systems Currently Used Manual Systems Manual Systems Log Books Log Books Manual worksheets, checklists and work orders Manual worksheets, checklists and work orders Electronic Systems Electronic Systems In-house generated electronic systems In-house generated electronic systems Off-the-shelf CMMS packages (computerized maintenance management system) Off-the-shelf CMMS packages (computerized maintenance management system) ERP’s (Enterprise Resource Planning) maintenance modules ERP’s (Enterprise Resource Planning) maintenance modules

5 Typical Log Book Entry No structure Incomplete/ambiguous entries

6 Excel Format Inconsistent terminology…must read and decipher all entries Mold layout requires manual trending

7 Typical W/O Format Single text field means no electronic correlation between defects above and corrective actions documented here. Single text field means no detailed reports concerning mold or part defects No connection to who repaired what defect

8 Why Don’t Typical Work Order Systems Work ? Illegible handwriting Illegible handwriting Incomplete data entries Incomplete data entries No structure to entries…scattered thought process No structure to entries…scattered thought process Inconsistent (non-standard) terminology Inconsistent (non-standard) terminology Manual “searching” for defects and corrective actions Manual “searching” for defects and corrective actions No data relationship between what was needed and what was done No data relationship between what was needed and what was done Toolmakers required to read and decipher entries to utilize Toolmakers required to read and decipher entries to utilize No visual impact No visual impact

9 Why Don’t Generic Asset Reliability Systems Work ? Generic terminology, structure and flow not intuitive to the run/repair cycle of a mold Generic terminology, structure and flow not intuitive to the run/repair cycle of a mold Many screen changes, cumbersome to use Many screen changes, cumbersome to use Critical information still buried in single text fields Critical information still buried in single text fields No visual connection No visual connection Bottom Line: Bottom Line: If toolmakers don’t like it…they won’t use it …

10 If a Maintenance System: Requires toolmakers and repair technicians to type or write subjective entries using inconsistent terminology into a single text field, then they are being paid to collect data…that no one will use. Requires toolmakers and repair technicians to type or write subjective entries using inconsistent terminology into a single text field, then they are being paid to collect data…that no one will use.

11 3 Basic Questions a Mold Maintenance System Should Answer What is your #1 unscheduled mold stop reason and associated corrective action costs? What is your #1 unscheduled mold stop reason and associated corrective action costs? What is your #1 mold issue or part defect? What is your #1 mold issue or part defect? What is your #1 mold with the highest maintenance costs (per hour of production) What is your #1 mold with the highest maintenance costs (per hour of production) All data related to these 3 questions needs to be easily sorted and viewed by: Mold number, product description, configuration, press, start and stop dates and times, associated personnel, tooling used and labor hours required.

12 What Are The Keys To A Successful Maintenance Software System? So then…

13 A Successful System Must 1 st Bring Value to the Toolmaker or the Repair Technician by being: Easy to use Easy to use Minimal typing Minimal typing Quick, on-the-fly data entry Quick, on-the-fly data entry Column headings to prompt correct entries Column headings to prompt correct entries Drop-down lists of standard plant terminology in critical fields Drop-down lists of standard plant terminology in critical fields

14 A Successful System Must 1 st Bring Value to the Toolmaker or the Repair Technician by being: Easy to understand Easy to understand Analyze past issues and repairs made quickly and accurately Analyze past issues and repairs made quickly and accurately Visual impact through digital images or drawings Visual impact through digital images or drawings

15 A Successful System Must Also Provide a Reporting Structure That Allows Supervisors, Managers and Engineers To: Analyze the true costs of mold maintenance by mold, configuration, product line or vendors. Analyze the true costs of mold maintenance by mold, configuration, product line or vendors. Monitor shop efficiency & employee performance Monitor shop efficiency & employee performance Set defect targets and mold performance goals Set defect targets and mold performance goals Optimize mold down time hours Optimize mold down time hours Reduce labor hrs. and maximize tooling life Reduce labor hrs. and maximize tooling life Budget wisely and more effectively Budget wisely and more effectively

16 And Finally…A Successful System Must Allow for future data skills growth. It does not make economic sense to purchase a W/O system that barely meets your current requirements, then spend time populating that data base with many molds and tooling. You are now handcuffed to a system that in time, will leave you wanting…and needing more. Allow for future data skills growth. It does not make economic sense to purchase a W/O system that barely meets your current requirements, then spend time populating that data base with many molds and tooling. You are now handcuffed to a system that in time, will leave you wanting…and needing more. MoldTrax 4.0 has many features that you may or may not initially use, and as shop data skills grow, these features will allow you to further standardize and track all aspects of your mold performance and maintenance efficiency. MoldTrax 4.0 has many features that you may or may not initially use, and as shop data skills grow, these features will allow you to further standardize and track all aspects of your mold performance and maintenance efficiency.

17 So what kind of data needs to be collected and utilized?

18 Typical Mold Information Collected

19 Fact Most companies already collect 80% of the information required to make informed decisions leading to dramatic improvements in mold performance and maintenance efficiency Most companies already collect 80% of the information required to make informed decisions leading to dramatic improvements in mold performance and maintenance efficiency They just don’t use it…

20 But now you can… Introducing

21 MoldTrax 4.0 What does it do ? MoldTrax 4.0 tracks the performance and maintenance of a variety of molds and dies, and has the capability to track different tooling configurations run in a single mold base. It then presents this information in over 25 unique reports. MoldTrax 4.0 tracks the performance and maintenance of a variety of molds and dies, and has the capability to track different tooling configurations run in a single mold base. It then presents this information in over 25 unique reports. How Does it work? Mold performance data is collected at the press and in the shop using specifically formatted work sheets, or entered directly into the software for a paperless system. Mold performance data is collected at the press and in the shop using specifically formatted work sheets, or entered directly into the software for a paperless system.

22 MoldTrax 4.0 Data Flow

23 So How is MoldTrax Different? Other systems: All other CMMS (computerized maintenance management systems) both large and small, utilize only one or two text fields in which to track work that is required and performed on a mold. All other CMMS (computerized maintenance management systems) both large and small, utilize only one or two text fields in which to track work that is required and performed on a mold. MoldTrax 4.0: MoldTrax 4.0: Provides “maintenance designed” formats that provide specific columns to enter data into which is quicker, more accurate and allows full utilization of the data. Provides “maintenance designed” formats that provide specific columns to enter data into which is quicker, more accurate and allows full utilization of the data.

24 The MoldTrax Method MT4 was designed with input from many toolmakers who spent their entire careers in the mold repair/refurbish field. It’s sole purpose is to track and report on the unique variables of mold performance and repair. MT4 was designed with input from many toolmakers who spent their entire careers in the mold repair/refurbish field. It’s sole purpose is to track and report on the unique variables of mold performance and repair. MT4 screens and data entry fields follow the logical progression of a typical run/repair cycle, so those not PC savvy can easily enter and utilize the data. MT4 screens and data entry fields follow the logical progression of a typical run/repair cycle, so those not PC savvy can easily enter and utilize the data. MT4 uses drop down lists to populate specific fields with your company specific terminology. This insures accurate and consistent data collection, and allows the data to be filtered and sorted for troubleshooting and reporting. MT4 uses drop down lists to populate specific fields with your company specific terminology. This insures accurate and consistent data collection, and allows the data to be filtered and sorted for troubleshooting and reporting.

25 MoldTrax 4.0 Features Easily accessible, comprehensive User Guide with many examples and images. Simply click on any section in the table of contents and it takes you there automatically!

26 Detail Mold Information Screen Live mold list…simply click on any mold and the data on the right side changes automatically in any of the 8 tab fields for instant comparison from mold to mold

27 Tooling Data Tab Categorize tooling for refined reporting Describe required tooling alterations, formulate change-over or repair kits, note drawer locations and other important tooling issues…double click any field to zoom!

28 Troubleshooting Guide Troubleshooting Guide Describe defect and list probable causes, corrective and preventative actions Paste digital images and drawings of mold or part defects…double click to zoom image! Standardize defect terminology for consistent reporting

29 Tech Tips Screen Tech Tips Screen Document critical or required steps/sequences used in disassembly, cleaning, assembly, final check and polishing procedures to standardize maintenance practices Paste images or drawings of part and mold

30 Maintenance Tracking Screen When you toggle through the mold run dates, all information on bottom half of screen changes accordingly for quick and accurate troubleshooting Track repair hours by job or specific corrective action Include a drawing or digital image of the defects noted during the production run…double click to zoom image! Add W/O number created in your ERP for document connectivity Track different tooling configurations run by a single mold base.

31 Maintenance Tracking Screen Tooling listed for this mold appears in the Corrective Action drop-down list for fast, consistent data entry and minimizes typing and random terminology.

32 Maintenance Tracking Screen Create a list of your Corrective Actions and track to see how shop hours are spent cleaning, replacement, adjusting, polishing etc…

33 Maintenance Tracking Screen Toolmakers and repair techs can quickly toggle back through repairs to see what tooling or corrective action was used to repair specific defects, and when.

34 Maintenance Tracking Screen Use this tab to schedule future maintenance activities by cycles or dates and track major mold events separate from normal PM’s Track current mold status and servicing frequencies

35 MoldTrax 4.0 Data Utilization

36 Specific Text Fields Mean Comprehensive Reporting

37 Single Mold Canned Reports (Statistical and Reference) Choose from the list of production run dates (Begin and End) for this mold Simply pick a mold from the drop down list Choose a Statistical or Reference report for any mold

38 New FastTrax Reports Simply type in any date range you want Then choose from over 20 unique reports presented in a spreadsheet format that allows you to compare many fields for complete data utilization

39 Target Unscheduled Downtime

40 Defect Type Analysis Report Shows Where to Focus Attention

41 Instantly Recognize Molds or Products With High Defect Counts Defects by Mold Block and Quality MoldDescriptionConfigurationTroubleShooters DefectsTypeBlockedQualityCount 5895Ress-Tubefeed "A"StandardFlash Threads at P/LPartNoYes ADH-Cup "C"StandardLong GatePartYesNo C21 ML VHC "H"StandardPull Ring FailurePartYesNo C18 ML VHC HelixHelixFlash on Pull RingPartNoYes ADH-Cup "C"StandardDrag on Frosted SkirtPartNoYes CBreak Cap "K"StandardVertical Flash Open EndPartNoYes SHinged CapStandardFlash Ejector PinPartNoYes ADH- Round CupStandardScuff on BodyPartNoYes Ress-Tubefeed "A"StandardHoriz. Flash Open EndPartNoYes9 6259Ress- ConnectorStandardVert. Flash (Small Open End) BottomPartNoYes CBreak Cap "H"ModifiedVertical Flash Open EndPartNoYes9

42 Track Maintenance Costs per Run Time Hour

43 Instantly See Tooling Costs by Mold, Description, Type, Quantity Used or Date Installed

44 Set Goals and Measure Results

45 Remember Your molds are the most critical and expensive link to the health and prosperity of your company. They deserve the complete and undivided attention that only a systemized approach can offer. MoldTrax 4.0 Track the past. Secure the future

46 MoldTrax 4.0 Setting A New Standard in Maintenance

47 About the developer… Steve Johnson works as the Maintenance Systems Manager for Progressive Components. Previous experience includes 7 years as Senior Maintenance Tooling Engineer for Abbott Laboratories/Hospira, a leading medical device manufacturer. His experience also includes twenty five years as a toolmaker at Calmar, Inc., redesigning and rebuilding high cavitation close tolerance multicavity molds. Prior to this, he served four years in the U.S. Navy as a jet mechanic training reservists on maintaining the A4L Skyhawk. Steve conducts nationwide seminars for ToolingDocs, on developing a systematic approach to mold maintenance. He also conducts maintenance capability assessments and hands-on training for plastics companies helping them to improve mold performance and shop maintenance efficiency. This experience has enabled Steve to design and develop MoldTrax 4.0, a unique comprehensive documentation system for tracking mold performance and maintenance from a “real world” perspective. This experience has enabled Steve to design and develop MoldTrax 4.0, a unique comprehensive documentation system for tracking mold performance and maintenance from a “real world” perspective. Steve has authored many articles for various plastics industry magazines including his columns Across The Bench found in Moldmaking Technology and Mold Shop for Plastics Technology..

48 MoldTrax 4.0 $2, for net workable version--- plus 5 additional seats in the same facility at no charge No annual fees. No annual maintenance costs. MoldTrax 3.0 users upgrade to free of charge Download 15 day full working copy for free from or, set up a personalized walk through of the system at your PC via a Webex connection or an in-house demo at your facility (1-2 hrs). Contact: Steve Johnson or Progressive Components Visit us on the web at The minimum system requirements to operate MoldTrax 4.0 are a Pentium III 1.2 GHz with 512 Meg of RAM and at least 100 meg of disk space free. Supported operating systems are Windows 2000, and XP Professional. Windows 95, 98, Me are not supported.


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