better way of organziing molding tools

[PEatCA]

Hi All

As per my new task is to organize the tools in plant. we have around 1000 molding tools, most of them has got tool ID and tool number, location is roughly defined,..but I system is not very efficient. depend on one system who looks after them during day shift and sign off from system but in nights no one is there to control on system so every one help themselves and leave tools on wrong locations etc etc.

I am open to any suggestions.

The target is have new system in place , with bar coding.
after certain period I want system to trigger that this tool is required a deep service...

thanks in advance

 

[MikeHalloran]

The problem is " every one help themselves ".
I'm guessing there is already a procedure,
probably written down,
probably posted on a sign,
... and ignored.

The task assigned is a complete waste of your time unless Top Management is prepared to enforce the rules they already have,
e.g. by docking the paycheck of anyone who 'forgets' the rules,
and if an individual can't be identified, by
docking the paycheck of everyone on that shift.

If it's a union shop, you have to get the union leadership involved enough to internalize the problem as a competence/ professionalism/ training issue, and let them take care of it within the union.



Mike Halloran
Pembroke Pines, FL, USA

 

[BillPSU]

I agree with Mike but want to add that if allowed I would do a video of a mold change over. I would then review the video picking out all activities such a going to a tool crib or searching for a tool or walking to get a tool to show some of the waste associated with the changeover.

Suggest a tool cart with all the necessary tools, hardware, slings, etc... to complete the specific changeover. The tool cart would be positioned to facilitate the changeover and have the operator help you design the cart and specify what is on the cart. This will lead you to pre-positioning molds and having specified areas to place the new mold and a place to put the mold being removed. There may be a need to have multiple carts depending on the complexity of the changeover.

Repairing worn molds is a different issue dealing with number of shots, allowable tolerance, finishes and a host of other issues.

Bill

 

[MikeHalloran]

Bill has the right idea; a mold change should run like a NASCAR pit stop, on a slightly slower time scale.

What is rarely apparent from TV coverage is that NASCAR crews 'kit' their replacement parts along with every tool needed to effect the change. A kit will be on a tray or in a drawer in a Lista cabinet, or maybe in one of those 'war wagons' they bring to the pits. The extra tools and tool cabinets and stuff are expensive, but way cheaper than losing a race.

Maybe in your case you need an array of quick-change die carts, one for each active mold, with all the tools you need, consumables like cleaning supplies already aboard, maybe even battery powered task lighting, whatever it takes to get the job done without personal injury or delay.
... all lined up in the order in which they'll be used (you do plan ahead, right?)
... and shuffled off to the mold clean/repair/preserve area,
from whence the carts are shuttled back into the 'to-use' queue,
or the molds are diverted to long-term storage and replaced with other molds.

The molds probably have some kind of numbers on them already. Putting those numbers into barcodes, or linking those numbers to arbitrarily numbered barcode tags, will make it easier to track the molds as they perambulate the premises.
... but only if everyone from top to bottom shows up with the self-discipline required to make any such system work. ... and of course that same self-discipline could make any system, including the one you have, work.

If you really want/need a system that could keep track of everything even if run by monkeys, go to Home Depot in the middle of the night. At least here in SoFla, you can buy a full propane bottle even when they are closed. You put your credit card in the machine, and a door slides open, somewhere. You put your empty bottle in there, and that door slides closed. Another door opens, and you remove a full propane bottle and take your receipt and your card. You could build a similar 'vending machine' for your molds. Maybe you can even buy one, given the state of our labor force.






Mike Halloran
Pembroke Pines, FL, USA