Redefining Mold Maintenance

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Redefining Mold Maintenance
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MaintenanceThe 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 todays 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 inventoryare 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.

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Typical Maintenance Culture

• Firefighting the hot issuesover and over
• Freelancing repairsno shop consistency or
  standardizationeveryone doing their own thing
• Documentation practicesjournal type W/O
  records with no structure and of little value
• Little communication with outside vendors
  concerning mold requirements or maintenance
  practices.

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Types of Systems Currently Used

• Manual Systems
• Log Books
• Manual worksheets, checklists and work orders
• Electronic Systems
• In-house generated electronic systems
• Off-the-shelf CMMS packages (computerized
  maintenance management system)
• ERPs (Enterprise Resource Planning) maintenance
  modules

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Typical Log Book Entry
No structure
Incomplete/ambiguous entries
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Excel Format
Mold layout requires manual trending
Inconsistent terminologymust read and decipher
all entries
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Typical W/OFormat
Single text field means no detailed reports
concerning mold or part defects
Single text field means no electronic correlation
between defects above and corrective actions
documented here.
No connection to who repaired what defect
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Why Dont Typical Work Order Systems Work ?

• Illegible handwriting
• Incomplete data entries
• No structure to entriesscattered thought process
• Inconsistent (non-standard) terminology
• Manual searching for defects and corrective
  actions
• No data relationship between what was needed and
  what was done
• Toolmakers required to read and decipher entries
  to utilize
• No visual impact

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Why Dont Generic Asset Reliability Systems
Work ?

• Generic terminology, structure and flow not
  intuitive to the run/repair cycle of a mold
• Many screen changes, cumbersome to use
• Critical information still buried in single text
  fields
• No visual connection
• Bottom Line
• If toolmakers dont like itthey wont use it

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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
  datathat no one will use.

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3 Basic Questions a MoldMaintenance System
Should Answer

• 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 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.

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What Are The Keys To A Successful Maintenance
Software System?

• So then

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A Successful System Must 1st Bring Value to the
Toolmaker or the Repair Technician by being

• Easy to use
• Minimal typing
• Quick, on-the-fly data entry
• Column headings to prompt correct entries
• Drop-down lists of standard plant terminology in
  critical fields

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A Successful System Must 1st Bring Value to the
Toolmaker or the Repair Technician by being

• Easy to understand
• Analyze past issues and repairs made quickly and
  accurately
• Visual impact through digital images or drawings

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A Successful System Must AlsoProvide a
Reporting Structure That Allows Supervisors,
Managers and Engineers To

• Analyze the true costs of mold maintenance by
  mold, configuration, product line or vendors.
• Monitor shop efficiency employee performance
• Set defect targets and mold performance goals
• Optimize mold down time hours
• Reduce labor hrs. and maximize tooling life
• Budget wisely and more effectively

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And FinallyA 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 wantingand
  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.

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So what kind of data needs to be collected and
utilized?
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Typical Mold Information Collected
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Fact

• 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 dont use it

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• But now you can
• Introducing

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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.
• 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.

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MoldTrax 4.0 Data Flow
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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.
• 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.

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The MoldTrax Method

• MT4 was designed with input from many toolmakers
  who spent their entire careers in the mold
  repair/refurbish field. Its 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 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.

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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!
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Detail Mold Information Screen
Live mold listsimply 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
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Tooling Data Tab
Describe required tooling alterations, formulate
change-over or repair kits, note drawer locations
and other important tooling issuesdouble click
any field to zoom!
Categorize tooling for refined reporting
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Troubleshooting Guide
Describe defect and list probable causes,
corrective and preventative actions
Standardize defect terminology for consistent
reporting
Paste digital images and drawings of mold or part
defectsdouble click to zoom image!
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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
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Maintenance Tracking Screen
Track different tooling configurations run by a
single mold base.
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 rundouble
click to zoom image!
Add W/O number created in your ERP for document
connectivity
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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.
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Maintenance Tracking Screen
Create a list of your Corrective Actions and
track to see how shop hours are spent cleaning,
replacement, adjusting, polishing etc
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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.
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Maintenance Tracking Screen
Use this tab to schedule future maintenance
activities by cycles or dates and track major
mold events separate from normal PMs
Track current mold status and servicing
frequencies
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MoldTrax 4.0 Data Utilization
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Specific Text Fields Mean Comprehensive Reporting
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Single Mold Canned Reports(Statistical and
Reference)
Simply pick a mold from the drop down list
Choose a Statistical or Reference report for any
mold
Choose from the list of production run dates
(Begin and End) for this mold
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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
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Target Unscheduled Downtime
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Defect Type Analysis Report Shows Where to
Focus Attention
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Instantly Recognize Molds or ProductsWith High
Defect Counts
Defects by Mold Block and Quality
Mold Description Configuration TroubleShooters Defects Type Blocked Quality Count
5895 Ress-Tubefeed "A" Standard Flash Threads at P/L Part No Yes 20
6870 ADH-Cup "C" Standard Long Gate Part Yes No 12
6454-C 21 ML VHC "H" Standard Pull Ring Failure Part Yes No 11
6471-C 18 ML VHC Helix Helix Flash on Pull Ring Part No Yes 11
6870 ADH-Cup "C" Standard Drag on Frosted Skirt Part No Yes 10
6889-C Break Cap "K" Standard Vertical Flash Open End Part No Yes 10
5413-S Hinged Cap Standard Flash Ejector Pin Part No Yes 10
6942 ADH- Round Cup Standard Scuff on Body Part No Yes 10
5895 Ress-Tubefeed "A" Standard Horiz. Flash Open End Part No Yes 9
6259 Ress- Connector Standard Vert. Flash (Small Open End) Bottom Part No Yes 9
6278-C Break Cap "H" Modified Vertical Flash Open End Part No Yes 9
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Track Maintenance Costs per Run Time Hour
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Instantly See Tooling Costs by Mold,Description,
Type, Quantity Used or Date Installed
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Set Goals and Measure Results
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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

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MoldTrax 4.0Setting A New Standard in Maintenance
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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.
• 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..

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MoldTrax 4.0 2,500.00 for net workable
version--- plus 5 additional seats in the same
facility at no chargeNo annual fees. No
annual maintenance costs.MoldTrax 3.0 users
upgrade to 4.0...free of chargeDownload 15 day
full working copy for free from www.MoldTrax.com
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).
ContactSteve Johnson419-289-0281
orProgressive Components800-269-6653Visit us
on the web at www.MoldTrax.com

• 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.