Sumitomo explains how caring for machines can increase production capacity and save time and money
Investing time and resources into injection moulding machinery to keep it in its best condition can lead to saving time and money, even potentially increasing production capacity
Operationally efficient injection moulding facilities require effective maintenance practices, involving a broad range of preventative measures targeting extending equipment lifespan, protecting tooling assets and workforce safety, and stopping machine breakdowns from interrupting production. It can also aid processors in monitoring energy consumption and identifying areas for improvement, which can eventually reduce demand on available energy sources.
Unplanned downtime can be costly and frustrating, as it results in no value being produced, while operational costs continue to grow. Nick Stockton, technical manager at Sumitomo (SHI) Demag UK and Ireland, said, “There are numerous benefits to having a well-maintained machine fleet. As well as increasing efficiency and extending the lifespan of equipment, machines that are well-maintained are also easier to service and diagnose issues when they arise. Additionally, because the machines are running at their optimal level, this also helps to reduce energy consumption.”
Care services
Sumitomo (SHI) Demag offers its customers services including time-based maintenance schedules, annual machine checks, and annual ErgoCheck tests. The ErgoCheck test examines each machine to ensure it is operating in accordance with the original manufacturer's protocols and design performance.
The company also offer an activeCare service, which checks performance and changes maintenance components, such as changing filters and exchanging batteries, or checking things like the toggle system and dosing speed.
More downtime, less value
Stockton said, “There are so many things we inspect for which can impede machine performance. From looking for cabinet hot points to checking the battery backups. All of which can help to break the cycle of reacting to emergency maintenance tasks.”
The most effective way for users to ensure both machine reliability and longevity is to carry out service work tasks as specified in the machine and user guides. Planned maintenance has a less significant impact on production line efficiency when compared with unscheduled downtime due to a failing machine part.
Stockton explained that one of the most common issues comes as a result of processors switching off the backup batteries for the weekend; the energy savings this provides can be negligible, yet it could lead to the entire software program needing to be reinstalled.
24/7 oversight
Machine data can be used to adjust service plans according to usage, instead of following set intervals for specific tasks, providing a customised and responsive plan.
Electric moulding machines offer built-in data gathering capabilities with parameters including acceleration and deceleration, forces, and motor duty cycles, all being checked by sensors.
The optimum time to change a part is just before it fails; the latest injection moulding machines make this possible with pre-emptive technology that informs users what maintenance is needed and any parts that need replacing in advance, anticipating issues before they cause any problems.
Condition monitoring, which uses thermographic equipment, is also a service included in the activeCare check, with engineers providing quantifiable measurements to determine when equipment or parts could fail in service.
Stockton said, “Being able to monitor, test and check all critical areas of machinery assets, using equipment that is calibrated to ISO 9001 and VDA 6.4 certification standards, helps instil confidence and provide early ‘red flag’ warning signs of potential problems.”
