MAPA DE EXPERIENCIA DEL CLIENTE

Integrity Tool and Mold De Mexico

project profile

Process Finish Cut

Project summary

The finish cut process is directly related to the defects (flash) presented in NB V1 tests

1. Pockets

2. ITM Canada

3. Machine

5. NB tests

4. Test bock

New components

Strategy

Promac VT

New Test

M5235

Feedback

Ball Scrul

Feedback

New Strategies

China Suppliers

VT machine presents displacement in Y axis of 0.003", is reviewed with supplier

Test block and NB tests will be applied with feedback from the visit to Canada

Application of tests in NB from job M5235

Tests will begin with pockets involving Gustavo Barrera and Jesus H. for the design of experiments

Test block tests continue to validate strategies to be tested in NB

Integrity Tool and Mold De Mexico

Application of strategies in New Building

Plastic piece

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Promac-004

01

machine used

Axis parallel 0°

02

Traslape 0.006" Slop Angle 90° Chord E. 0.00004"

50.38 Hrs

03

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Integrity Tool and Mold De Mexico

CMM Report

Statistic analysis

Integrity Tool and Mold De Mexico

Application of strategies in New Building

DMG 210P

01

machine used

Curve Parallel

02

Traslape 0.0065" Slop Angle 90° Chord E. 0.00004" inside out (piece-stamp)

40.5 Hrs

03

Plastic piece M5330

Time Machining

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Integrity Tool and Mold De Mexico

CMM Report

Statistic analysis

Results May 2023

Project progress in Machining process

Process standardization and Cpk

Standarization

New Strategies By Andres López

Standards are created to program different types of molds based on their geometry.

PLastic Piece

2 options

3 Options

Seal

4 Options

Cut & Pockets

Reductions

2 Options

May analysis

12 Molds

Cpk 0.47

There is an improvement in the Cpk of the process based on the standardization of machining strategies

The new strategies are being applied in 12 new molds

HSM Cpk in May, improvement of more than 100% vs baseline (0.22 Cpk in 1st quarter of 2023)

DMG 210P

Axis Parallel with dynamic machining

The machine with the highest precision within the May analysis

The strategy that is giving us better results vs DMG Mori machines

Goal Cpk 1.00

Machine validation

Machine condition review to improve machining performance

Promac VT

Promac Zephir VT

Excessive Run out (0.0015") Axis A (0.0019") Action plan:

• Validate with Promac supplier the balance of the spindle
• A axis aligns with tolerance table
• Validate effectiveness of RTCP

DMU 125

Excessive Run Out (0.027") Table misaligned:

• 0°: 0.0039"
• 90°: 0.0039"
• 260° 0.0039"

Action Plan

• Validate with DMG suppliers the balance of the spindle
• Adjust table with FCS
• Validate effectiveness of RTCP

Qualification

M5330

Mold in spotting

• Mold presents collision in padlocks
• Point on right side higher (0.005")
• Boxes and seal line with good finish
• 24 Hours of adjustment approx.

Qualification

M5241

Mold in spotting

• Machining burrow in pockets
• Ruff in pockets 1-6
• Offset hub housing (Axis X positive)
• Analyze variables (program, assembly, alignment, FCS)

Action plan

Analyzed machine

Preventive Maintenance

PerformanceMachining

Variable Tracking

Variation in machine

Intervened machines

Foundry/IAS

RTCP/Laser Tracking

• Promac VT
• 125U
• Promac 004
• Promac 002 Today is validated

• VT (the spindle nose will be seated to remove impurities and corroborate that the run out is correct, the measurements with the bar are correct to Promac standards.)
• DMG (Continued validation with supplier)

Foundry is being assimilated for analysis of displaced machining

Analysis of machines in conjunction with maintenance

Machining Status (Review)

Promac 004

Vibration

• Y axis needs ballscrew replacement
• Lubrication problems.

Maitenance Plan

Review type

Detection

Schedule

Review

step 1

Axes lubrication is reviewed, kinematics is programmed later

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Premature wear is detected in machines

Complete revision is scheduled (1st week of July)

Machines are requested for review

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Strategies

Reduction of machining strategies to standardize the programming process By Andrés López

• Axis Parallel
• Curve Parallel
• Curve Parallel with dinamic machining
• Axis paralle with dinamic machining

• Axis Parallel with dinamic machining
• Curve Parallel

Machine Analisys

A regression analysis is carried out on 17 jobs with a final machining process on all HSM machines, yielding the following results

Recommended strategies for machines

Machine Analisys

• Machine lubrication is reviewed in HSM.

• It is expected to schedule a review of kinematics this month to validate eX with correct nominal variation

Machine Analisys

Promac004 Analysis Pockets

Analysis of the following jobs is taken (PROMAC 004):

• M5285
• M5328

Strategye:

• Z constant

• Variation in right direction (x axis 0.004 +- 0.001)

Table FCS

Table FCS

M5328

M5385

Validate variation in pockets by axis and spindle kinematics

Machine Analisys

DMG 210P Analysis Pockets

Analysis of the following jobs is taken (210P):

• M5326
• M5329

Strategye:

• Z constant

• Variation in right direction (x axis 0.004 +- 0.001)
• (C Axis 0.004 +- 0.001)

Table FCS

Table FCS

M5329

M5326

Validate variation in pockets by axis and spindle kinematics

Machine Analisys

Strategies to follow

• Multiple problems are reported in HSM machines
• Strategies are adjusted but the problem is in machine condition
• We must invest time and money in repairing machinery
• Perform preventatives more frequently and firmly
• Perform corrective plus exaustuvs with complete revision of axes
• Carry out predictive machinery plan
• Track collisions and errors with operators (reports)

Variation in Jobs

Lack of calibration

Unvalidated kinematics

Run out

Vibration

Next steps for maintenance of CNC machines

Machine CNC

Maitenance Plan

intervened machines

Machines adjusted in tolerance

P7 key activities

Tasks to do

48 hours per machine

Required time

Resources

Staff and spare parts

Capability Analisys

Job (M5302 Tycos Tool and Die)

1.3

Cpk Goal

Machine (Promac-002/003)

+50%

CPk (0.61)

20%

Out of spec

+30%

Z potential

Protocol for collisions

In development process by Cristian Mora

1. This protocol must be activated at the moment of a spindle collision with a mold in process.
2. The operator must report to the maintenance team with a Ticket and completely stop the machine until it is attended by the team in question.
3. The protocol process is calculated to be carried out between 4 to 6 hours depending on the damage detected after the incident.
4. The machine cannot and must not be operated after a spindle collision until the maintenance team releases it.

Ball scrub status is validated to keep rou out within parameters

runout validation

Ballscrub

Machine kinematics with patterns is validated

Kinematics

spindle position

Axis

axis validation

Axes and origin positions are validated

Damage to the spindle and bearings is reviewed to identify damage (Avoid the case of 125U)

Splinder

spindle status

It seeks to ensure the integrity of the machine with this protocol, in turn we have Andrew's support in case of suspected collision in the machine and avoid cases where spindles are damaged for not reporting collisions and continue operating the machine

Instruction for revision of post-collision cnc equipment and poor finishes

SCOPE

SUPPORT

Maitenance Managers (Shop, Schedule, Quality) Manufacturing Team Quality Team Purchasing Team

Specification "what to do in case of collisions and bad finishes"

Objetive

Establish a structured and efficient process for the review and maintenance of machines after collisions or similar incidents that significantly compromise the integrity of the machine or the quality of the work to be processed.

FOLLOW

GOAL

Internally auditable formats Management support to reinforce instruction

Avoid "DMG120U" cases with high repair costs

Info

all machines and equipment with CNC characteristics

Next Steps

Programming Group

Program validation (Standard Method)

reviews

Implement controls for programming

Controls

Programming

Program review (lessons learned)

Follow-Up

Audits to controls and programming standards

Aug 2023 (W34)

Sep 2023 (W36)

Aug 2023 (W35)

Sep 2023

• At the beginning of the project there is a percentage of defects of more than 90% of inefficiency (+-0.002")
• By carrying out the improvement and standardization work, a 45% reduction in defects has been achieved with respect to the month of March (base line).
• In August, the jobs show a stabilization percentage of 90% within the requested tolerances (+-0.002") vs. March with 70% of points within tolerances.

Summary Results

Base Line vs August

Only Seal

Cpk Analysis

Cpk August

Aug 2023 (W34)

Sep 2023 (W36)

Aug 2023 (W35)

Sep 2023

Project V1

Summary

New Steps

• Address pocket hollowing with new tools and machining strategies
• Address variation of verticals with adjustment of programming parameters
• Address reductions with new tools and adjustment of programming parameters

Seal+-0.002" Improve 47%

Verticals

Pockets

+0.002"0.000" New Item

+-0.001New Item

Reductions

Critical SPC for mold machining

01

03

04

02

LSE : 0.05 mmLIE: -0.05 mm Cpk : 0.72 Z Bench: 2.10 % Out of Spec: 1.77

Seal

LSE : 0.07 mmLIE: -0.02 mm Cpk : 0.10 Z Bench: 0.15 % Out of Spec: 43.85

Verticals

LSE : 0.05 mmLIE: -0.02 mm Cpk : 0.07 Z Bench: -0.25 % Out of Spec: 59.81

Pockets

Radios

LSE : 0.07 mmLIE: 0.00 mm Cpk : 0.03 Z Bench: -0.25 % Out of Spec: 59.79

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New SPCs for mold machining are analyzed, including tool tests and parameter changes in programming

Project Scope Extension

Actions to follow

• Seal band process stabilizes
• analysis process is integrated for verticals/pockets/radios and reductions
• Machining vs CMM references are analyzed to reflect proper measurement
• FCS machining process is analyzed to adjust its correct position
• Spotting presses instruments are analyzed to validate heights (benches and table)
• We proceed to analyze parallelism of spotting presses and plates

Machining Strategies

01

Stable machining strategies (stamp line), focus on reductions, radiuos and pockets

Measuring system

02

Define references for block measurement (Z axis)

Team involved

Mold Making

• Miguel Garrido (MM Expert)
• Roberto Ruiz (Metrologist)
• Gustavo Barrera (Engineering)
• Joe Jeffrey (Manufacturing)

03

Validate presses (parallelism) and plates, validate benches and tapping table

• Carlos Estrada (Shop)
• Rafael Delgado (Quality)
• Patricia Cruz (QMS)
• Christian Mora (Maintenance)
• Francisco Olán (Continuous Improvement)

Capability Analysis Pockets

7 key activities

Maitenance Review

• Instant replacement
• Shaft vibration check
• Check for hydraulic leaks
• Accumulator pressure check
• Spindle lubrication review
• Cleaning of drivers and electrical cabinet

Capability Analysis Verticals

Staff and spare parts

Investment and release of workload

Carlos is currently managing the necessary resources to provide maintenance and personnel support to cnc machines

• Counterbalance Hydraulic Cylinder
• lubrication valves
• grease bomb
• filters
• 5 people

Capability Anayisis Seal 2023

Intervened machines

Adjusted machines

• Promac 002
• Promac 004
• Promac VT Zhepyr
• DMG 125U

Capability Analysis Radios

Capability Analisys

M5302 Tycos Tool an Die