Bazele Injectiei Mase Plastice

CONFIDENTIAL
[Injection Section]
Model Change Standard Manual
Introduction
Electronic industry during the Digital Age has shortened the Life Cycle of the product dramatically, and in a situation where prices change quickly, continuously introducing new products and reflecting the needs of various customer has been prioritized as the main factor for the companys survival. Especially, the increase of material cost due to recent Won currency boost and high petrol cost, the cost price pressure is growing, Japanese companies efforts, thanks to the structure adjustment and internal economic recovery, are concentrating on strengthening their expansion on their lead in the market. Our company must playing the leading role, by establishing a rational Process in order to expand the cost and speed competitiveness. Especially, as for our company and vendors in which the foundation is based on increase in production amount, production system operation of various products variable, On time 3 Days Fixed Production Plan, Fixed amount production, we must ensure that the company and vendors Model Change time be shortened in order to achieve a World Class Corporate. In such aspects, we would like to provide the drive methods to improve the people involved by themselves at the manufacturing site, by making use of the Press Equipment Model Change Standard Manual. The purpose for developing this Press Equipment Model Change Standard Manual is : First, Third, Speed insurance through Model Change Time Single Systemization. Establish an Effective Factory through Standardizing Model Change Work Process and Improvements. The core capability in the Electronic industry is speed. I believe that this Press Equipment Model Change Standard Manual is a compulsory guide to achieve the World Class Corporate. Through continuous improvements and preservation, we request for your active usage to create a competitive factory.
Second, Improve Operation Rate and Capa. through Model Change time shorten.
September 2006 Corporate Business Innovation Team Vice President Yoon Ju Hwa
Content
. Check List . Overview . Model Change Work Order
Attachment Documents Attachment 1. Improvement steps for Model Change Single Systemization Attachment 2. Model Change Work Improvement Point Attachment 3. Improvement Cases
. Check List
Ejection Model Change Standard Manual

1. Outer Preparation Check
Stanrd Work Order 01 02 03 04 05 06 07 08 09 10 11 12 13 14 15 16 17 18 19 20 Obtain Production Plan from the Supervisor Create Model Change Chart Management Point 30mins before work 20 mins before work Std. Time(S) 300 30 30 120 60 30 40 30 60 60 10 10 Check Eye-Bolt Connection Appoint Mould Waiting Area 10 300 10 Indicate Center Indication 3 mins before Model Change Standard Valve color Check Coolant Removal 30 5 5 60 PIC B Page 18 PIC B Page 16 Page 17 PIC B Page 15 PIC A Page 14 PIC B Page 12 PIC A Page 10 PIC PIC A Ref. Page 9
Go to Mould Storage Area with the Hoist 90 mins before Model Change Find the Mould for Model Change and Connect to Appoint Mould Storage Address the Hoist Move the mould for Model Change to Pre-Heating Locate Pre-Heater near Injection Waiting Area Machine Connect the Mould for Model Change to PreBefore (Pre-Heating Time + Heater 10mins) Check Pre-Heater's Temperature Setting and Mould Temperature +% Check For Leaks After Connecting the Valve Gate Heater, Set Melting Temperature 90% the Temperature Find the Appropriate Tool Cart from the Tool 10 mins before Model Change Storage Move the Tools Cart to the Facility Area Store Tools in Tool Storage Move the Hoist to the Pre-Heating Mould Separate the Pre-Heater from the Mould Off the Heater Power and Disconnect the Wires Connect the Pre-Heated Mould to the Hoist Move the Pre-Heated Mould to the Model Change Injection Machine Separate the Pre-Heated Mould from the Hoist Move the Hoist to the Upper Injection Machine Close Production Mould Coolant In/Out Valve Open the Air Out Valve Supply Air and Remove Coolant Residue 10 mins before Model Change Check Mould Temperature
PIC B
2 Inner Check List

Standard Work Order 01 02 03 04 05 06 07 08 09 10 11 12 13 14 15 16 17 18 19 Swith Injection Machine to Manual and stop Switch OFF the Heater Controller Power Use Injection Machine Nozzle Lever to Retreat Nozzle Open Injection Machine Front Safety Door Apply Grease on the Mould Surface Open Injection Machine Back Safety Door Separate Coolant Hose on Fixed Side Separate Coolant Hose on Moving Side After applying Grease, Check for Errors on Inner Mould Close the Mould Manually Lower Hoist onto Mould Separate Heater Connector Separate Air hose Separate Timer Wire Connect Production Complete Mould to Hoist Connect Hoist and Mould Release Auto Clamp Pressure Separate the Gasket Separate 2 fixed side, 2 moving side clamps Management Point Mesasure Model Change Time Standardize Nozzle Retreat Distance Maintain Rust, Core Parts Std Time(s) 2 2 5 15 5 10 10 5 Check PIC B Completion Standardize Connector Pin 5 20 10 10 10 15 5 10 10 10 PIC A PIC A PIC Ref. Page 19 Page 20 Page 21
PIC A
PIC B
Page 23
PIC B PIC B PIC A PIC A
Page 24 Page 25 Page 26
Check Eye-Bolt Connection Make the rope tight
Revised Date :

2. Inner Preparation Check List
Standard Work Process 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 42 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 Separate Clamp upon PIC A's Signal Open Injection Machine's Moving Plate Manually Separate Production Complete Mould from Injection Beware of Locate Ring Damange Machine Move Production Complete Mould to Assigned Area Add Legs to Mould Check the Model of the Model Change mould from Check Injection Condition Injection Machine Input After Model Check, Retrieve Injection Condition Check Injection Condition of Model Change Mould Separate Hoist from Production Complete Mould Connect Hoist to Model Change Model Move Model Change Mould to Injection Machine Lower Model Change Mould to Injection Machine Stick Locate Ring to Injection Machine Center Mould Locate Ring and Injection Nozzle Input Gas Conditions of Model Change Mould Check and Adjust Heater Supplier Close Auto Clamp to Mould Switch ON and Fix Auto Clamp Control Box Connect Fixed Side Coolant Host Connect Moving Side Coolant Hose Lower Hoist and Loosen the Line Separate Hoist from Mould Move Hoist to Production Complete Mould Location Adjust Mould Thickness in Injection Control Panel Open Mould Climb Up Injection Machine and Connect Wires Connect Air Hose Connect Timer Wire Open Injection Machine Front Safety Door Clean Grease on Inner Mould Set Injection Machine Cooling Conditions Set Heating Conditions Set Gas Supplier Conditions Forward Injection Machine Cylinder Squeeze out Over-Heated Resin inside Nozzle Switch Injection Machine to Semi-Auto Adjust Detail Injection Conditions Inspect until Production Record Model Change Time Inspection Standard Check Resin Residue inside Mould Prepare Hand Rug Standardize Surrounding Components per Equipment Check Air Supply Check Cooling Block Check In/Out Connection Check Mould Plate Thickness Indicate Center Check Eye-Bolt Connection Management Point Std Time(s) 10 10 5 50 30 5 25 15 15 20 30 30 15 30 30 10 10 15 15 10 15 20 20 5 10 10 10 5 30 10 10 10 12 30 5 5 120 PIC A Page 41 PIC A Page 40 PIC B Page 39 PIC A Page 38 PIC B Page 37 PIC B PIC A,B PIC B PIC A PIC B PIC A PIC B Page 36 Page 35 Page 32 Page 33 Page 34 PIC A Page 31 PIC A Page 30 PIC B Page 29 PIC A Page 28 PIC PIC B Ref. Page 27
3. Outer Preparation Check List

Standard Work Order 21 22 23 Move Proudction Complete Mould to Mould Storage Indicate Completion on Model Change Chart Move Model Change Cart to Waiting Area Management Point Std TIme(s) 300 20 60 PIC PIC B PIC A Page 42 Ref.
Revised Date : 2006.09.11 Revised Date :
PIC A Check List

Standard Work Order 01 Obtain Production Plan from the Supervisor 02 Create Model Change Chart 03 Go to Mould Storage Area with the Hoist the 04 FindHoistMould for Model Change and Connect to the mould for Model Change to Pre-Heating 05 Move theArea Waiting 09 Find the Appropriate Tool Cart from the Tool Storage 10 Move the Tools Cart to the Facility Area Management Point 30mins before work 20 mins before work 90 mins before Model Change Appoint Mould Storage Address Locate Pre-Heater near Injection Machine 10 mins before Model Change Store Tools in Tool Storage Std Time(s) 300 30 30 120 30 60 Std Time(s) 2 2 5 15 5 5 20 5 10 10 10 10 5 50 15 15 20 30 30 15 10 10 10 20 5 30 12 30 5 5 120 Std Time(s) 20 60 Page 23 Page 25 Page 26 Page 20 Page 14 Ref. Page 9
Page 10

Standard Work Order Management Point Ref. 01 Swith Injection Machine to Manual and stop Mesasure Model Change Time 02 Switch OFF the Heater Controller Power Standardize Nozzle Retreat 03 Use Injection Machine Nozzle Lever to Retreat Nozzle Distance 04 Open Injection Machine Front Safety Door 05 Apply Grease on the Mould Surface Maintain Rust, Core Parts After applying Grease, Check for Errors on 09 Inner Mould 10 Close the Mould Manually Check PIC B Completion 11 Lower Hoist onto Mould 16 Connect Hoist and Mould Make the rope tight 17 Release Auto Clamp Pressure 18 Separate the Gasket 19 Separate 2 fixed side, 2 moving side clamps 21 Open Injection Machine's Moving Plate Manually 22 Separate Production Complete Mould from Beware of Locate Ring Damange Injection Machine 23 Move Production Complete Mould to Assigned Area Add Legs to Mould 27 Separate Hoist from Production Complete Mould 28 Connect Hoist to Model Change Model Check Eye-Bolt Connection 29 Move Model Change Mould to Injection Machine 30 Lower Model Change Mould to Injection Machine 31 Stick Locate Ring to Injection Machine 32 Center Mould Locate Ring and Injection Nozzle Indicate Center 35 Close Auto Clamp to Mould Check Mould Plate Thickness 36 Switch ON and Fix Auto Clamp Control Box 39 Lower Hoist and Loosen the Line 42 Move Hoist to Production Complete Mould Location 47 Open Injection Machine Front Safety Door 48 Clean Grease on Inner Mould Prepare Hand Rug 52 Forward Injection Machine Cylinder Check Resin Residue inside 53 Squeeze out Over-Heated Resin inside Nozzle Mould 54 Switch Injection Machine to Semi-Auto 55 Adjust Detail Injection Conditions 56 Inspect until Production Inspection Standard 57 Record Model Change Time
Page 19
Page 28
Page 30
Page 31 Page 33 Page 35 Page 38
Page 40
Page 41

Standard Work Order 22 Indicate Completion on Model Change Chart 23 Move model change cart to waiting area Management Point Ref. Page 42
Revised Date : 2006.09.11
PIC B Check List

1. Outer PreparationCheck List
Standard Work Process 06 Connect the Mould for Model Change to Pre-Heater 07 Check Pre-Heater's Temperature Setting and Check For Leaks 08 After Connecting the Valve Gate Heater, Set the Temperature 11 Move the Hoist to the Pre-Heating Mould 12 Separate the Pre-Heater from the Mould 13 Off the Heater Power and Disconnect the Wires 14 Connect the Pre-Heated Mould to the Hoist 15 Move the Pre-Heated Mould to the Model Change Injection Machine 16 Separate the Pre-Heated Mould from the Hoist 17 Move the Hoist to the Upper Injection Machine 18 Close Production Mould Coolant In/Out Valve 19 Open the Air Out Valve 20 Supply Air and Remove Coolant Residue Std. Time (s) Before (Pre-Heating Time + 10mins) 60 Management Point Mould Temperature +% Melting Temperature 90% 10 mins before Model Change Check Mould Temperature Check Eye-Bolt Connection Appoint Mould Waiting Area Indicate Center Indication 3 mins before Model Change Standard Valve color Check Coolant Removal 30 40 60 10 10 10 300 10 30 5 5 60 Page 15 Ref.
Page 12

Standard Work Process 06 07 08 12 13 14 15 20 24 25 26 33 34 35 36 37 38 40 42 43 44 45 46 49 50 51 Management Point Std. Time (s) 5 10 10 10 10 10 15 10 30 5 25 30 30 10 10 15 15 15 20 5 10 10 10 10 10 10 Page 39 Page 29 Ref. Page 21
Open Injection Machine Back Safety Door Separate Coolant Hose on Fixed Side Separate Coolant Hose on Moving Side Separate Heater Connector Standardize Connector Pin Separate Air hose Separate Timer Wire Connect Production Complete Mould to Hoist Check Eye-Bolt Connection Separate Clamp upon PIC A's Signal Check the Model of the Model Change mould from Check Injection Condition Injection Machine Input After Model Check, Retrieve Injection Condition Check Injection Condition of Model Change Mould Input Gas Conditions of Model Change Mould Check and Adjust Heater Supplier Close Auto Clamp to Mould Check Mould Plate Thickness Switch ON and Fix Auto Clamp Control Box Connect Fixed Side Coolant Host Check Cooling Block Connect Moving Side Coolant Hose Check In/Out Connection Separate Hoist from Mould Adjust Mould Thickness in Injection Control Panel Open Mould Climb Up Injection Machine and Connect Wires Connect Air Hose Check Air Supply Connect Timer Wire Standardize Surrounding Set Injection Machine Cooling Conditions Components per Equipment Set Heating Conditions Set Gas Supplier Conditions
Page 32 Page 33 Page 34 Page 35 Page 36
Page 37

Standard Work Process 21 Move Proudction Complete Mould to Mould Storage Management Point Std. Time(s) 300 Ref. Page 42
. Overview
1. Definition of Model Change 2. Purpose of Model Change 3. Target of Model Change 4. Methods of Model Change 5. Preparation for Model Change Single Systemization 6. Understanding Injection Structure
1. Definition of Model Change

Time taken to complete the current production and producing a product after changing the model Product Standard : A product which passes the inspection based on Inspection Standards
2. Purpose of Model Change

Creating a Flexible manufacturing site producing quantity in accordance to the selling speed, establishing fixed time, fixed quantity structure through Supply Management Process Shorten Manufacture Lead Time Reduce ManufacutureStorage Improve Operation Rate (Improve Model Change Loss : Preparation, replacement, adjustment etc.)
3. Target of Model Change

Target of Model Change: Single Systemization
4. Methods of Model Change

Injection Machine Model Change should be based on 2 people.
5. Preparation for Injection Model Change Single Systemization

Item Preparation Install Auto Clamp(QMC) Create Channel for Equip. Locate Ring Center Display Mould Condition Chart Install Coolant Assemble Block Standardize Ejector PIn Location Standardize Mould Fixed Plate Mould Thickness Indicate Mould Center Location Standard Method - Upon vendor approval and purchasing new injection machine, appoint as compulsory clause - Standardize locate ring height - Create locate ring guide for injection machine fixed side - Find the conditions for optimum production, create condition chart and manage by displaying it on site - Manufacture cooling assble block during mould production Include this clause as compulsory upon mould approval - Standardize Ejector Hole Location per mould Include this clause as compulsory upon mould approval - Standarize mould fixed plate thickness according to Clamp(QMC) standard (Manufacture additional T -Block if needed) - Indicate centre for mould production Include this clause as compulsory upon mould approval Page 22,34 Page 36 Page 33 Page 31 Page 16,28 Page 59 Page 12 Page 32,37 Page 12 Page 14 Page 19,40 Page 17,30 Page 10,16,35 Page 16 Ref. Page 26,33 Page 69
Add Mould Protection - When loading mould, add legs for mould oil pressure core, coolant hose production and to Legs replace wooden plates Standardize Eye-Bolt Install Pre-Heater One Touch Systemization for Hose Joint Area Prepare Valve Gate Heater Standardize Tool Cart Standardize Cyclinder Retreat Location Indicate Hoist Stop Location Install Hoist Hook Appoint Mould Waiting Area beside Machine
People
- Standardize Eye-bolt joining parts and Eyebolt color according to mould size - While model change, install pre-heater to shorten mould temperature increasing waiting time - Create One Touch systemization to shorten time when separating and connecting coolant - Install heaters in previous injection machines using valve gate to remove waiting time - During model change, create and utilize compulsory tool carts - Standardize injection machine nozzle retreat distance according to injection machine capacity - To reduce adjusting time of injection machine and mould centre, indicate arrows along hoist moving rail - For easy tightening of mould and hoist, stick hook on rope connected to hoist - Appoint waiting area for before and after model change (nearby injection machine)
Oth. Equip.
Oth.
Operate Model Change - Ensure model change work professionalism by PIC appointing model change Person-In-Charge
6. Understanding Injection Structure

1) Injection Mould Structure
10 9
1 2 15 16 8 3 11
P/L
4 5 6 7
12 13
14
No. 1 2 3 4 5 6 7 8
Name Fixed Install Plate Fixed Plate Moving Plate Spacer Block Upper Ejector Plate Lower Ejector Plate Moving Install Plate Core
No. 9 10 11 12 13 14 15 16
Name Locate Ring Sprue Bush Guide Pin Ejector Sleeve Core Pin Ejector Pin Angler Pin Side Core
2) Equipment Structure
Injection Equipment
Hopper
Form Equipment
Oil Pressure Controller
BED (Bed)
Parts Bed Form Equipment
Details Base for installing form, injection. oil pressure, electronic equipment Equipment which closes mould so that mould doesn't open - Fixed part, moving part, tie bar, form cylinder, thickness adjusting equipment, Ejector, safety door Made up of hopper measuring materials and screw cylinder in charge of injection - Hopper : Storage apparatus used for storing material to be supplied to screw cylinder
Injection Equipment
Oil Pressure Control Oil Controlling part supplying operation rate Equipment
This manual is based on 850T Valve Gate Injection Machine

6
. Model Change Work Order

1. Model Change Standard Cycle Chart 2. Detailed Model Change Work Standard
1. Model Change Standard Cycle Chart

Work Work Item Order Time(s) Factor Work A B 1min 2min 3min 4min 5min 6min 7min 8min 9min 10min Time Cycle Chart
Ref. (before) 30 mins
01 Obtain Production Plan for Day 02 Create Model Change Chart 03 Move to Mould Storage Area 04 Find Mould, Connect Hook 05 Move to Pre-Heat Waiting Area 06 Connect Mould to Pre-Heater O u t e r P r e p a r a t i o n 07 Set Temperature, Check for Leak 08 On Heater, Set Temperature 09 Prepare Tools 10 Move to Facility Area 11 Move Hoist to Pre-Heating Mould 12 Separate Pre-Heater from Mould 13 Separate Heater 14 Connect Finished Mould to Hoist Move to Model Change Injection 15 Machine Separate Finished Mould from 16 Hoist Move Hoist to Upper Injection 17 Machine 18 Block Coolant IN/OUT Valve 19 Open AIR OUT Valve 20 Insert AIR to remove remainder Outer Preparation Subtotal 01 Stop Injection Machine 02 Off Heater Power 03 Retreat Injection Machine Nozzle I n n e r P r e p a r a t i o n 04 Open Front Safety Door 05 Apply Grease on Mould 06 Open back safety door 07 Separate Fixed Coolant Hose 08 Separate Moving Coolant Hose 09 Check Mould Interior 10 Close Mould 11 Lower Hoist 12 Separate Heater Connector 13 Separate AIR Hose 14 Separate Timer Wire 15 Connect Hoist to Eye-Bolt 16 Connect Final Hoist 5 5 5 20 10 10 10 15 2 2 5 15 5 10 10 30 60 60 10 10 10 300 10 30 5 5 60 570 630 10minutes 30 seconds 300 30 30 120 60 30 40
20 mins
90 mins
60 mins 20 mins 10 mins
10mins

Work Work Item Order Work Factor Time(s) A 10 10 10 10 5 50 30 5 25 15 15 20 30 30 15 30 30 10 10 15 15 10 15 20 20 5 10 10 10 5 30 10 10 10 12 30 5 5 120 9 minutes 47 seconds B 10 Time Cycle Chart 1min 2min 3min 4min 5min 6min 7min 8min 9min 10min Ref.
17 Release Clamp Pressure 18 Separate Gasket 19 Separate Clamp 20 PIC B Separate Clamp 21 Open Moving Plate 22 Separate Previous Mould from Injection Machine 23 Move and Lower 24 Check Injection Condition 25 Set Conditions 26 Check Conditions 27 Separate Finish Mould From Hoist 28 Connect Model Change Mould to Hoist 29 Move Mould 30 Lower Model Change Mould to Injection Machine 31 Adjust Locate Ring I n n e r P r e p a r a t i o n 32 Adjust Nozzle Center 33 Prepare Gas Supply 34 Prepare Heater Supply 35 Add Clamp 36 Tighten clamp 37 Connect Fixed Part Coolant Hose 38 Connect Moving Part Coolant Hose 39 Lower Hoist 40 Separate Hook 41 Move Hoist 42 Adjust Mould Thickness 43 Open Mould 44 Connect Heater Wire 45 Connect Air Hose 46 Connect Timer Wire 47 Open Front Safety Door 48 Clean Grease Inside Mould 49 Set Coolant Conditions 50 Set Heater Conditions 51 Set Gas Conditions 52 Forward Injection Cylinder 53 Squeeze Resin 54 Change Machine to Semi-Auto 55 Set Detailed Injection Conditions *56 Product Out and Check
P r e p a r
* Time depends on product's cycle time : Based on Cycle Time of 60s second product
O u t e r -
57 Record Model Change Time Inner Preparation Sub-Total 587 Move Mould Beside Injection Machine to 01 300 Mould Storage Indicate Complete on Model 02 20 Change Chart 03 Arrange Model Change Carts 60 Outer Preparation Sub-Total 300
5 minutes
2. Detailed Model Change Work Standard
Oth.Prep -01 Create Current Model Change Chart
PIC A
1) Process
1. Obtain Production Plan of the day 2. Create Model Change Chart
2) Work Standard
(1) Obtain Production Plan of the day A. Get production plan from the supervisor : 30 minutes before work (2) Create current model change plate A. Record as "Model Change Chart" in the production plan: 20 minutes before work
3) Management Point
(1) Record pre-heating time and ensure pre-heating time doesn't overlap.
Improvement Observations
Injection Machine Model Change Chart
1st August 2006
Equip. NO Name 1 850MG Model Before 34D20 AFter 34D11 Mat. Col.
Model Change Expected Time
Mould Temp. 50C
H/R Temp 220C
Pre-Heat Start Time 10:50 End Time 11:30 PIC
HF1690
11:40
Hong
Oth.Prep -01
Move Mould to Mould Pre-Heat Area
PIC A
1) Process
1. Move to Mould Storage 2. Find Mould, Connect Hook 3. Move to Pre-Heat Waiting Area
2) Work Standard
(1) Move to Mould Storage Area : 90 minutes before A. Adjust hoist according to model change plan and move to mould storage area (2) Find Mould, Connect Hook A. In the mould storage, look at mould storage location sheet and confirm mould location. B. Lower the hoist pulled and connect the hook of the hoist to the mould's Eye-Bolt. (3) Move to Pre-Heat Waiting Area A. Pull up the hoist and move the mould to PreHeat waiting area. While using movable pre-heat equipment, move mould near to assigned mould change injection machine B. After lowering the mould at the Pre-Heat Waiting area, separate the hook C. Stick the pre-heat waiting number on the mould according to order.
Mould Storage Location Sheet Eye-Bolt&Hook
3) Management Point
(1) Assign Address to mould storage so that it would be easy to locate them (2) For fixed type pre-heater, place it at a maximum distance from the mould storage (3) Mould Storage must concur with the current sheet and the mould
Improvement Observations (1) Indicate Location in Mould Storage & Operate Location Sheet Setting (Appoint Address)
10
Mould Storage Location Indication

Address Equipment Number
Place Indication
Address Number
Number
Color Arrangement
Main Passage
A B C
50L3
P S a u s b s a g e
32Z10 Low Usage Moulds
Code NO. 50L3 32Z10
Location Length Width A 1 B 3
No. A1 11 B3
Product Name F/C B/C
Injection Machine 1,300TON 850TON
Ref.
11
Oth. Prep - 03 Connect Pre-Heat Hose to Model Change Mould PIC B
1) Process
1. Connect mould to pre-heater 2. Set temperature, check for leaks 3. Connect heater, set temperature
2) Work Standard
(1) Connect Pre-Heater : (Pre-Heat time + 10mins)before A. According to order of model change chart, move the model change mould to the pre-heater location. Pre-Heat time could vary greatly due to Pre-Heater's amount and mould size B. Connect Pre-Heater's IN line connector to mould's coolant block IN line C. Connect Pre-Heater's OUT line connector to mould's coolant block OUT line D. Open the temperature adjusting valve starting from the OUT line, then open the temperature adjusting valve of IN line (2) Set temperature, Check for leaks A. On the power of pre-heater B. Check if pre-heater is functioning C. Set the pre-heater's water temperature as +% of the mould temperature according to the respective mould's condition chart and check for circulation D. Check for leaks on mould and block (3) Connect heater, set temperature A. Connect the valve gate wire connector to the mould's connector, adjust the left and right B. On the valve gate heater power C. Set the valve gate heater's temperature
Heater Controller Pre-Heater
12
3) Management Point
(1) Check water circulation of mould with eyes : water drop's flow (2) Set pre-heater water temperature : +% of product's condition chart (3) Check for errors on valve gate temperature (Set temp to current temp) - Heater controller temperature standard should be about 90% of the melting temperature of resin being used (4) Checking for achieving mould temperature can be done by adding the magnetic temperature on the mould chart to see if set temperature and surface temperature concur
(1) Standardize cooling hose IN/OUT joint point color Ex) IN(Blue), OUT(Red) (2) Establish mould pre-heating system (3) Stick mould coolant block
Standardize color code Stick cooling block
13
Oth. Prep -04
Prepare Model Change Tools
PIC A
1) Process
1. Prepare Tool Cart 2. Move to Site Area
2) Work Standard
(1) Tool Cart Preparation : 10 minutes before A. Move to Model Change Tool Cart Storage and search for the tool cart (2) Move to facility area A. With the tool cart, return to injection facility and store at site
3) Management Point
(1) Make sure there are no tools missing needed at model change (2) Check the availability of grease and others
(1) While using tool cart, minimize borrowing of tools from moving and narrow area to longest distance - Tools needed : 'L' wrench SET, spanner, hammer coolant nipple, grease, etc. (2) Minimize model change tools by reducing the number of tools by apply One Touch System and others at the connecting areas
14
Oth. Prep- 05
Separate Mould from Pre-Heater
PIC B
1) Process
1. Move hoist to preheating mould 2. Separate mould from pre-heater 3. Separate heater
2) Work Standard
(1) Move hoist to pre-heating mould : 10 minutes before A. Move hoist to the pre-heating mould of the pre-heating area (2) Separate pre-heater from mould A. Before separating pre-heater, check using magnetic temperature if the mould's temperature has risen to the set temperature Pre-Heater equipped with pre-heat completion lamp, check the preheat completion lamp B. Off the Pre-heater power C. Block the IN, OUT valve connected to the pre-heater and mould to block the coolant supply D. Remove remaining coolant E. Pull the hose fix lever at the left, right side of cooling hose end, separate the 2 hose from the mould and hook it to the pre-heater hook (3) Separate heater A. Off the heater controller's power B. Pull back the fix lever at the end of left, right side of the heater wire connected to the upper mould, arrange the wire after separating connector

3) Management Point
(1) Prepare a hook to arrange the hose or wire
15
Oth.Prep -06
Move Pre-Heated Mould to Injection Machine
PIC B
1) Process
1. Connect Pre-Heated Mould to Hoist 2. Move to Mould Change Injection Machine
2) Work Standard
(1) Connect Pre-Heated Mould to Hoist : 10 minutes before A. Lower hoist using hoist adjuster B. Connect mould's Eye-Bolt using hoist hook (2) Move to Model Change Injection Machine A. Move the mould connected to the hoist by using to model change injection machine B. Lower mould at assigned area near injection machine Connect Hook
3) Management Point
(1) Check if mould waiting place has been assigned near injection machine
(1) While adding legs to lower mould, it will save time when lowering the mould - Prevent lower mould oil pressure core, slide core, coolant fitting damage 2) Mould lowering place must be indicated on the moving rails of the hoise to reduce moving time - Mould waiting area must be assigned
Assign mould waiting area Add legs
16
Oth.Prep -07
Move Hoist to Upper Injection Machine
PIC B
1) Process
1. Separate Pre-Heated Mould from the hoist 2. Move Hoist to Upper Injection Machine
2) Work Standard
(1) Separate Pre-Heated mould from hoist : 5 minutes before A. Separate hook of pre-heated mould moved to nearby injection machine (2) Move the Hoist to Upper Injection Machine A. Move hoist using the hoist's wire lever button B. Adjust the injection machine and hoist center in a line C. Move the hoist wire to near the injection machine control panel, quickly locate it to the place of model change
3) Management Point
(1) Adjust the arrows along the hoist moving rail to the arrows indicated on the walls of lower rail and adjust the hoist to the center of injection machine
(1) Before mould change, adjust the hoist to center of the injection machine and prepare moving time (2) To reduce center adjust time, apply a sensor to hoist moving location to auto-stop
Adjust Hoist Center
17
Oth.Prep- 08 Remove remaining coolant in current mould
PIC B
1) Process
1. Block coolant In/Out Vavle 2. Open Air Out Valve 3. Inject Air to Remove Residue
2) Work Standard
(1) Block Coolant IN/OUT Valve : 3 minutes before A. After moving hoist, move behind injection machine B. Block coolant supplier IN/OUT line's fixed and moving side's belt (2) Open AIR OUT Valve A. Open Air valve connected to the coolant supply equipment OUT line (3) Inject AIR and remove residue A. Open Main Air connected to IN line, and when air is supplied into mould and water exits, wait for 1~2 minutes and check with eyes B. Set the coolant supplier temperature according to the facility chart of appropirate pre-heat conditions of the model change mould
Block OUT OUT Valve IN Valve Block IN
3) Management Point
(1) Check for any decreasing pressure of pressure gauge installed in the mould's residue removal system and check for remaining substances being removed (2) Standardize coolant hose IN/OUT joint areas Ex) IN(Blue), OUT(Red)
18
In.Prep-01
Stop Injection Machine and Retreat Nozzle
PIC A
1) Process
1. Stop Injection Machine 2. OFF Heater Power 3. Retreat Injection Machine Nozzle
2) Work Standard
(1) Stop Machine : Start Model Change A. When last injection is complete, mould opens and product ejected, change injection machine to manual and stop the injection machine (2) OFF Heater Power : 2 seconds A. Press Off button on heater controller and off (3) Retreat Nozzle : 2 seconds A. Use nozzle retreat lever on control panel and retreat injection nozzle
3) Management Point
(1) Add Timer on injection machine and time Model change from the beginning
Machine Stop TIMER
00h 00m 00s


(1) Standardize nozzle retreat according to injection machine's amount (Reference : Vacuum Cleaner 200mm, VD 300mm)
19
In. Prep - 02
Apply Grease on Mould
PIC A
1) Process
1. Open Front Safety Door 2. Apply Grease on Mould
2) Work Standard
(1) Open Front Safety Door : 5 seconds A. With current mould OPEN, open the front safety door (2) Apply Grease on Mould : 15 seconds A. Apply appropriate amount of grease on completed mould surface with 20cm gap from the fixed side's mould B. When fixed side is completed, apply using same method on moving side
3) Management Point
(1) Greased should be equally spread on the mould surface by shaking UpDown, DownUp

(2) For long-term storage with moulds rusted or core, apply ample amount to prevent rust
Grease Applyinbg Order
(1) Spread evenly to prevent mould's rust
Apply Grease
20
In.Prep - 03
Separate Cooling Hose from Mould
PIC B
1) Process
1. Open Back Safety Door 2. Separate Fixed Side Cooling Hose 3. Separate Moving Side Cooling Hose
2) Work Standard
(1) Open Back Safety Door : 5 seconds A. PIC A waits behind model change injection machine till stop B. When injection machine stops, open back safety door (2) Separate Fixed Side Cooling Hose : 10 seconds A. Holding end of fixed side mould IN line hose, pull the fixed lever and unlock B. After unlocking,pull the hose with both hands and separate the mould C. Same steps as 1), 2) is applied to fixed side OUT line hose (3) Unlock moving side coolant hose : 10 seconds A. Same above steps are applied for moving mould IN,OUT line
Separate Cooling Hose
3) Management Point
(1) The separated cooling hose should be placed where it won't be disturbed during moving of the mould - Use cooling hose hook
Arrange Cooling Hose
21
(1) To achieve Model Change Single Systemization, coolant block in mould must be installed first
Coolant Block Install Case
22
In.Prep - 04
Close Mould and Lower Hoist
PIC A
1) Process
1. Check Inner Mould 2. Close Mould 3. Lower Hoist
2) Work Standard
(1) Check Inside Mould : 5 seconds A. After applying grease, do a final check inside the mould B. After checking for mould errors, close safety door of the injection machine
Mould Check Inside
(2) Close Mould : 5 seconds A. At the control panel, turn the mould close switch left slowly and close the moving mould manually (3) Lower the Hoist : 20 seconds A. After closing mould, press hoist adjustor lower button to lower hoist
3) Management Point
(1) Before closing mould, PIC B must disconnect coolant and check if it has been moved to a safety area
23
In.Prep - 05
Disconnect Heater, Timer, Air Hose
PIC B
1) Process
1. Disconnect Heater 2. Disconnect Air Hose 3. Disconnect Timer
2) Work Standard
(1) Disconnect Heater Connect : 10 seconds A. After disconnecting coolant, go up injection machine and wait till mould close B. Pull out connector by pushing heater connector fix lever on upper mould left and right (2) Disconnect Air Hose : 10 seconds A. Disconnect Air hose with same method above (3) Disconnect Timer wire : 10 seconds (In case of a successful mould) A. Disconnect Timer wire with same method above
Disconnect Timer, Air Hose , AIR Disconnect Connector
3) Management Point
1) Disconnected surrounding connectors should be arranged and hung on hook so not to disturb lowering of mould
1) Standardized heater connectors PIN numbers to improvement replacement time during model change (Vacuum Cleaner : Standardize to 16PIN)
Standardized to 16 PINS
24
In.Prep - 06
Connect Mould's Eye-Bolt and Hoist
PIC A, B
1) Process
1. Connect Eye-Bolt and Hoist 2. Hoist Final Connection
2) Work Standard
(1) Connect Eye-Bolt and Hoist(PIC B) : 15 seconds A. Lower the hook on manila rope to a position possible to connect to a completed mould's Eye-Bolt
Eye-blot& Connect Eye-Bolt & Hook
B. After connecting hook to mould's Eye-bolt, send completion signal to PIC A (2) Hoist Final Connection(PIC A) : 5 seconds A. PIC A must slowly press the upper button on the hoist adjustor until the hoist line becomes tight, then lift it up to check the connection for the final time
3) Management Point
Center
1) Before connecting hook, turn the Eye-Bolt connected to the mould, and check if it's been connected fully
10Cm
1) Reduce connecting time by using hook on manila rope 2) Move location of hoist to be 10cm parallel to the moving mould's side (To allow easier separation of locate ring in the next procedure)
Moving Plate 25 Fixed Plate
In.Prep - 07
Separate Auto Clamp(QMC)
PIC A
1) Process
1. Release Clamp Pressure 2. Separate Gasket 3. Separate Clamp
2) Work Standard
(1) Release Clamp Pressure : 10 seconds A. Ensure hoist is tight, and prepare for Auto Clamp separation B. Change Clamp Adjustor lever to 'Change' (2) Separate Gasket : 10 seconds (Apply when gas) A. While clamp pressure is reducing, separate gasket inside the mould
Separate Gasket
(3) Separate Clamp : 10 seconds A. After checking Auto clamp pressure has reduced, send separation signal to PIC B B. Pull 2 clamps on fixed side and separate C. Pull 2 clamps on moving side and separate
Separate Clamp
3) Management Point
(1) Check if Auto clamp's pressure gauge is '0'
Check Pressure Gauge
(1) For model change single systemization, Auto Clamp(QMC) must be applied.
QMC : Quick Mold Chager AUTO Clamp Apply AUTO 26
In.Prep - 08
Separate PIC B Clamp
PIC B
1) Process
1. Separate PIC B Clamp
2) Work Standard
(1) Separate PIC B Clamp : 10 seconds A. After separating upper mould's injection surrounding components, climb down behind injection machine and wait B. After receiving separation signal from PIC A, prepare for oil pressure clamp separation C. Pull 2 clamps on fixed side and separate D. Pull 2 clamps on moving side and separate
AUTO Clamp Separate Auto
3) Management Point
(1) After completely separating the clamp, inform completion to PIC A
AUTO Clamp Apply AUTO
27
In.Prep - 09
Separate Completed Mould and Move
PIC A
1) Process
1. OPEN Moving Plate 2. Separate completed mould from injection machine 3. Move and Lower
2) Work Standard
(1) OPEN Moving Plate : 10 seconds A. After checking separation completed signal from PIC B, using injection control panel's clamping switch and open moving plate manually (2) Separate completed mould from injection machine : 5 seconds A. Check if mould's locate ring is ejected from injection machine B. Raise the mould on hoist vertically and eject from injection machine (3) Move and Lower : 50 seconds A. Move completed mould to the assigned place beside injection machine
3) Management Point
(1) While separating mould, ensure locate ring is not damaged by hitting the injection machine (2) Move completed mould to model change mould and reduce time by using hoist
(1) Add legs on mould to improve support work while lowering (2) Assign a place to lower mould and must indicate section
Add Mould Legs
28
In.Prep - 10
Recall Injection Conditions
PIC B
1) Process
1. Search Injection Conditions 2. Recall Conditions 3. Check Conditions
2) Work Standard
(1) Search Injection Conditions : 30 seconds A. Take out Auto Clamp and move it in front of the injection machine B. Press the memory button on injection machine's control panel, and search for the model change mould's name using the up-down button (2) Recall Conditions : 5 seconds A. Check the model name and select "Recall" (3) Check Conditions : 25 seconds A. After Recall of injection conditions of the appropriate model, check for any errors
3) Management Point
1) Maintain and manage that the mould's injection condition data file in possession are saved in the injection machine.
Recall Injection Conditions
29
In.Prep - 11
Move Model Change Mould
PIC A
1) Process
1. Separate Completed Mould from Hoist 2. Connect Model Change Mould to Hoist 3. Move Mould
2) Work Standard
(1) Separate Production Completed Mould from Hoist : 15 seconds A. After lowering completed mould, separate hook connected to Eye-Bolt B. Move hoist to model change mould (2) Connect Model Change Mould to Hoist : 15 seconds A. Connect model change mould's Eye-Bolt to hook connected to hoist (3) Move Mould : 20 seconds A. Lift model change mould and move to injection machine B. Match arrows indicated on the hoist moving rail to the arrows indicated on the crane
3) Management Point
(1) Turn model change mould's Eye-Bolt and check if it's completed connected
Adjust Hoist Center
(1) Indicated stop sign on hoist and crane to reduce hoist moving time.
30
In.Prep - 12
Fix Model Change Mould to Injection Machine
PIC A
1) Process
1. Lower Model Change Mould to Injection Machine 2. Adjust Locate Ring 3. Adjust Nozzle Centre
2) Work Standard
(1) Lower Model Change Mould to Injection Machine : 30 seconds A. Adjust model change mould center to injection machine's center, lower. B. Using mould "Close" lever on injection machine's control panel, close moving plate to mould fixed side (2) Adjust Locate Ring : 30 seconds A. Adjust hoist minutely and move locate ring close to injection machine B. Using hoist adjustor's left-right button to adjust hanging mould's parallel (3) Adjust nozzle center : 15 seconds A. Adjust the mould's locate ring with the nozzle center moving side to about 30cm and push the mould to
3) Management Point
(1) Adjust mould and injection machine's center line. (2) Check in advance the locate ring's damage on mould to prevent problems after model change.
Indiciate Mould and Injection Machine's Center
(1) Make a locate ring guide hole on injection machine's fixed plate to reduce mould lowering time. (2) Adjust locate ring's height and manufacture Taper's end to allow easy fitting.
Make Taper Taper Height 20mm
31
In.Prep- 13
Prepare Gas, Heater Supply
PIC B
1) Process
1. Prepare Gas Supply 2. Prepare Heater Supply
2) Work Standard
(1) Prepare Gas Supply (Based on Gas Using Model) : 30 seconds A. Insert gas conditions of model change mould into gas supplier (2) Prepare Heater Supply : 30 seconds A. Check for any errors on heater wire B. Check for errors on each heater controller's functions C. Check if heater temperature matches the model change mould temperature and adjust
3) Management Point
(1) After checking for any errors on heater controller, if there is, replace the controller.
(1) Change gasket connection parts to One-Touch Connection method. (2) Standardize connector Pin Type of Heater Controller
One GasketOne Touch Touch Connection System
32
In.Prep - 14
Connect AUTO Clamp(QMC)
PIC A, B
1) Process
1. Move Clamp 2. Connect Clamp
2) Work Standard
(1) Move Clamp : 10 seconds seconds A. When mould closes completely, PIC A sends signal to PIC B to prepare for clamp connection B. PIC A must push 2 fixed side clamps, 2 moving side clamps to mould's fixed plate closely C. PIC B must also push 2 fixed side clamps, 2 moving side clamps to mould's fixed plate closely (2) Connect Clamp : 10 seconds A. When PIC B sends completion signal, PIC A must "ON" the control key on clamp control box and fix the clamp.
3) Management Point
(1) Check if mould plate's thickness is according to clamp standards (VD : 850ton Below : 45mm, 1,000ton Above : 80mm) (2) Check clamp pump's gauge and check by pulling the clamp using hand - Clamp Pressure follows product's Spec
Connect Clamp AUTO AUTO
33
In.Prep - 15
Connect Cooling Hose
PIC B
1) Process
1. Connect Fixed Side Cooling Hose 2. Connect Moving Side Cooling Hose
2) Work Standard
(1) Connect Moving Side Cooling Hose : 15 seconds A. After clamp connection is completed, insert fixed side's coolant hose IN line connector to fixed side's mould coolant block blue connector B. Tighten fixed lever at end of both temperature controller connector and connect C. Insert fixed side's coolant hose OUT line connector to fixed side mould coolant block red connector, tighten fixed lever and connect (2) Connect Moving Side Coolant Hose : 15 seconds A. Apply the same method above for moving side's coolant hose
3) Management Point
(1) Check hose's connectivity on coolant block and hose connected to mould (2) Check if the connectivity is according to IN, OUT color
(1) For model change Single systemization, coolant block must be installed in mould
Add Coolant Block
34
In.Prep - 16
Separate mould hoist within equpment
PIC A, B
1) Process
1. Lower Hoist 2. Separate Hook 3. Transfer Hoist
2) Work Standard
(1) Lower Hoist : 10 second A. After PIC A checks clamp connection, using hoist's controller, lower the tight rope until above mould and loosen. B. At this point, after PIC B connects clamp, go up the mould in advance and wait (2) Separate Hook : 15 seconds A. When rope loosens, after separating mould, send signal to PIC A. (3) Transfer Hoist : 20 seconds A. After PIC A checks that hook is separated, move hoist to completed mould location.
3) Management Point
(1) Before separating hook, pull oil pressure clamp and check if properly connected (2) After PIC A checks that hook is completely separated, move the hoist
(1) After changing end of manila rope to hook, rope connection and separation time will be reduced.
35
In.Prep - 17
Adjust Mould Thickness
PIC A
1) Process
1. Adjust Mould Thickness 2. Open Mould
2) Work Standard
(1) Adjust Mould Thickness : 20 seconds A. After moving hoist, switch "Mold Set" to On on injection machine's control panel. B. Find "Thickness Adjustment" on control panel and On. C. Look at mould thickness adjustment completion indication lamp and check (2) Open Mould : 5 seconds A. After mould thickness adjustment completion, open mould
3) Management Point
1) After adjusting thickness and mould opens, press the Eject button and check the movement conditions of the Ejector Pin
1) If the location of Ejector pin and size is standardized, Ejector Pin Replacing time could be Zero
Standardize Pin Ejector Ejector
36
In.Prep-18
Connect Heater, Air Host, Timer Wires
PIC B
1) Process
1. Connect Heater Wire 2. Connect Air Hose 3. Connect Timer Wire
2) Work Standard
(1) Connect Heater Wire : 10 seconds A. Once mould is fixed into equipment, go up injection machine and insert mould's connector according to heater wire's left, right channel B. After connecting the connector, pull the fixed equipment found on mould connector's left, right inwards, and fix the inserted wires. (2) Connect Air Hose : 10 seconds A. Hold the Air supply hose, push and fit the air hose insert nipple found on mould (3) Connect Timer Wire (Sequence Injection) : 10 secs A. Insert and fix the timer connector wire using the same application as heater wire B. After connecting injection surrounding components, come down from the machine
(1) Change Air hose connection parts to One Touch method to reduce time
Improve One One touch Touch
37
In.Prep - 19
Clean Grease
PIC A
1) Process
1. Open Front Safety Door 2. Clean Grease Inside the Mould
2) Work Standard
(1) Open Front Safety Door : 5 seconds A. When mould moving plate opens, open the front safety door (2) Clean Grease Inside the Mould : 30 seconds A. Prepare cleaning tool(hand rug), go inside the mould, then clean the grease applied on surface of mould's fixed side using up, down strokes B. Clean the grease applied on mould's moving side using up, down strokes
3) Management Point
(1) Grease is left on mould's bottom edges so pay attention. - If grease is not removed, it will stick onto product during production
(1) If glove-type hand rug is used to fix hand in, cleaning time can be reduced. (2) If a thin sponge can be added inside on the cleaning part, it would be useful for cleaning
38
In.Prep - 20
Set Coolant, Heater, Gas Conditions
PIC B
1) Process
1. Set Coolant Conditions 2. Set Heater Conditions 3. Set Gas Conditions
2) Work Standard
(1) Set Coolant Conditions : 10 seconds A. Move to injection machine's coolant controller, open IN line valve B. Open the coolant controller's OUT line too, and press the "DRIVE" switch on temperature controller to function. C. Press on each "Water Maintenance" switch, "Cold Water", "Heater" switch to function D. Check if each lamp is functioning normally, and match temperature (2) Set Heater Conditions : 10 seconds A. Switch ON the heater controller power and press the power switch on each cell to switch ON B. Set if temperature setting on thermometer's each cell indicating screen is set according to surrounding component's condition chart (3) Set Gas Conditions : 10 seconds (For Gas Usage) A. Recall gas equipment's injection conditions, and check each stage's pressure and time, then maintain the equipment at manual
[Standardize Chart per ] [ Machine]
(1) Standardize of surrounding components per injection machine, such as the chart on right.
39
In.Prep - 21
Squeeze RESIN
PIC A
1) Process
1. Forward injection Cylinder 2. Squeeze Resin 3. Switch Injection Machine to Semi-Auto
2) Work Standard
(1) Forward Injection Cylinder : 12 seconds A. After cleaning the grease, use the Transfer Level of the control panel to forward the retreated injection cylinder, nozzle close to the mould (2) Squeeze Resin : 30 seconds A. Use injection measuring lever of control panel to squeeze the overheated Resin in mould's valve gate from previous LOT production and in the nozzle B. Open injection machine's safety door, go inside, remove the squeezed Resin to make the mould surface clean (3) Switch Injection Machine to Semi-Auto : 5 seconds A. Come out of the injection machine, close the safety door, and move the operator lever on control panel to semi-auto location
3) Management Point
(1) Ensure that the squeeze resin does not remain on mould surface.
Set Cylinder Retreat
(1) Indicate location to reduce cylinder forward and retreating time
Location
40
In.Prep - 22
Sample Injection
PIC A
1) Process
1. Adjust Detailed Injection Conditions 2. Eject Product and Injection 3. Record Model Change Time
2) Work Standard
(1) Adjust Detailed Injection Conditions : 5 seconds A. Close MouldInject Cooling(Amount)Check the production in progress, move to injection machine's control panel, and adjust detailed injection conditions (temperature, pressure) (2) Eject Product and Inspect : 120 seconds A. When product is ejected after production is complete, inspector waiting judges pass or reject according to the product standards B. Proceed if product passes, re-inject again if rejected, then inspect and check until product passes 120 seconds based on 2 products whose Cycle Time is 60 seconds (3) Record Model Change Time A. If product passes, record the model change time, and proceed
3) Management Point
1) Execute sample inspecting according to Inspection Standards. - Using assigned tools, inspect measurement per Inspection Point, formation. 2) Prepare acceptable limit sample, and compare with first product.
1) Inform model change on day schedule to inspection department in charge to prevent problems on inspection manpower, limit sample, and ensuring Inspection Standards
41
In.Prep - 08
Arrange After Model Change
PIC A, B
1) Process
1. Move Mould beside Injection Machine to Mould Storage 2. Indicate Completion on Model Change Chart 3. Arrange Model Change Cart
2) Work Standards
(1) Transfer Mould beside Injection Machine to Mould Storage Area A. Connect hoist to model change completed mould and transfer to mould storage area. B. After checking Mould Storage Location, return to its position. (2) Indicated Completion on Model Change Start A. Indicate Model Change on Model Change Chart to mark model change completion and check the next model change. (3) Arrange Model Change Cart A. Transfer model change cart to the waiting area.
3) Management Point
1) Make sure to store mould according to the location shown on the mould location chart.
42
Attached Documents
Attachment 1. Improvement Step for Model Change Single Systemization Attachment 2. Model Change Work Improvement Point Attachment 3. Improvement Cases
Attachment 1. Improvement Steps for Model Change Single Systemization

Analyze Current Situation
, (VTR), Change Analysis Inspect Site(VTR Record), Model

Chart Divide to clauses possible to change oth. preparation during Model Change Work Change Waste
Inspect Model Change Actual, Categorize Model
1 STEP
Separate In, Oth Preparation
2 STEP
Waste Improve
/ (, , )
Improve In./Oth.Preparation Work's Waste (Preparation, Replacement, Adjustment, etc.)
Preparation systemization of 3 STEP Oth. Preparation
In Preparation
In. Preparation Work
4 STEP
Standardization, , Commonization
Execute manual work of LCA, Automation, JIG, etc LCA, , JIG
Others
Model

Change
Preparation
Work
Divide
In/
Work
Situation
Analyze
Oth. CS / In Out In. ot P ma Preparation r mn Out I e Preparation Oth. od m p P n a Oth. Preparation i r In. W p a r In. a r r e z d Preparation Work In. s o Preparation a p a i Preparation t v t a Preparation tz e e i r ia o a 1 STEP 2 STEP 3 STEP o t 4 STEP n t ni i o o n n
43
Attachment 2. Model Change Work Improvement Point

1. Preparation Waste Removal Point
1) Whichever that can be prepared in advance should be prepared
(1) In.Preparation Work to be prepared before model change
2) Hands can be moved, but not feet

(1) Preparation work consists of searching, selecting, transportation work. (2) During model change, it is important not to make more than 3 footsteps.
3) Improvements for Preparation Waste removal

(1) Develop Exclusive Model Change Cart (2) Manage Mould Location (Address Systemization) (3) Set Model Change Order (4) Make Model Change Check List (5) Set Systemization of Model Change Tools (6) Model Change Work Division according to Model Change Labor (7) Create Work Order Chart and Standardize (8) Arrange, Neat, Properly, Clean (9) Account for the Number of Tools (10) Adopt Utilization, Scale, and Dial (11) Assign Mould and Tools Near To Equipment (12) Methods to Place Beside for Mould Transportation (13) Clean After Container is Cassette Systemized of Equipment Functioned Revised Date : 2006.09.11
44
Preparation Waste Improvement Observations

Items Before Improvement Form and ToolsFindStart Looking Transfer After Improvement Experiment with Excluse Model Change Cart
Form Plate's 7 Types of Tools
Model
Change
Exclusive
Cart
Form Form Oil Grease
Press's Mould Storage Location is not clear, taking a long time to search
Where is it...
Regards to Mould Storage, Address System to indicate Address and Number

Form Store Tag
Mould's
Address refers to a group's room number
Address
System
Kit
System
Arranged per product, size and form. Kit system for Jig, Stick Section, Gauge, Appropriate Meansuring Section per product
Punch Store Glue Tool Store Measuring Insp. Tools For Product A
For Product B
For Product C
45
Items
Before Improvement
After Improvement
Production Plan
Worker
Look at Production Plan and stick model change card
Product a
Empty Cart
Tech.
Stick Manufacture Degree
Excluse Cart
Mould
Lift Form
Excluse Cart
Model
Change
Sticking Section
Set Model Change Order.

Inspection Section
Order
Model Check the site Change Worker
Execute Model Change
Cart
After completing ~ , start backwards While model change, record inconvenient Points Refer to Clause A07 for model change tag
46
Items
Before Improvement Only after starting a model change, tools not available were found.
After Improvement Make a Check List of Model Change. Ex)

Items Types Spanner, Tighener ... Micrometer, Measuring Tool. Lubrication, Grease ... Tools
C h e c k L i s t
Where's the cover?
I must prepare a Check List!
Measuring Tools
Oil
Spanner Driver Wrench Hammer

As they have forms, it is easily noticed when missing.
Model
Change
One thing noticed from the model change was searching for tools for model change and start looking.
Set up a system for model change tools, then use when necessary
Tools
When I need it...
47
Items
Before Improvement If one person works, he must work in and around the facility causing unwanted waste while moving
After Improvement Create a divided team with works divided (Machine never stops.)
1 Team 2
Person System
Assemble the jig..
Safety first!
Model
Change
Create standard work chart, set an Although model change worker was assigned to tasks, worker had a lot order for worker's participation. of waiting time. Model change is Model Change Chart not easy for a new work as it Prod. Prod. Time requires adjustments, efforts and No. Name experiences. NO Preparation Qty. Check Degree
1 2 3 4 5 a. b. c. d. e.
Order
Chart
1. Lift mould to cart and use bolt... Oth. 2. 3.
Stop the equipment and execute 5S.
Before starting model change, after preparation, begin cleaning after functioning.
Model
Change
Zero
Arrange
Neat Clean Order
5 S
48
2. Replacement Waste Removal Point

1) Do not tighten or loosen bolts. 2) Completely remove the bolts. (1) Function of bolt is to be used as deciding the tightening and location of substitute area 3) The standard never changes.(Standard Principle of Fixture) 4) Improvements for Replacement Waste Removal (1) Do not take out Bolt, tighten by turning once. (2) Uniform height of tightening spots. (3) Can be done with a small Nut and C-Type Washer. (4) When Joint Torque is small, systemize Pin and Block. (5) One Touch tightening using a handle type. (6) Create a common system for each jigs. (7) Do not move standards by space by Unit or by Work (8) Use spring types rather than screws. (9) Systemize One touch Cassette (10) Minimize model change by with common jigs. (11) Combine mould and jigs to reduce numbers.
49
Replacement Waste Improvement Observations

Items Before Improvement Adjust jig's joining height to the steel bracket, and tighten Bolt and Nut. Do not use stand during replacement.
Steel Bracket
After Improvement Dependent Joint Area Do not take out the Nut. Do not put in the stand. Can tighten Nut with 1 turn.
Spring Spring
Uniform Joint Height
Step
JIG
Stand
Type Stand
Snow Man Type Hole C Type

Washer
During form change, dismantle all bolt, washer and jig.
Jig to be Snowman Type Hole, do not take out the Bolt. Small Type Bolt, Nut + C Type Washer
Bolt Nut
Washer
Length is different per Work. P i n B l o c k

Deciding location to be adjusted with Bolt's measurements.
When joint torque is small, systemize Pin and Block. (Sticking Pin and turning it is good enough)
Pin Pin Ball
50
3. Adjusting Waste Removal Point

1) Do not move the base of manufacturing product (1) Each time manufacturing standards differ as manufacturing products change, do not change the base which is hard to change, change only the ends which are easy to move 2) Systemize all adjusting work looking at scales as Block Gauge 3) Create Stopper and Guide 4) Improvements for Replacement Waste Removal (1) Systemize Full Set as others model change. (2) Do not take out the Set. Replacement only partial parts. (3) Experiment common jigs. (4) Systemize Block and Guide for mould's location decision. (5) Standard decision should be a clash method. (6) Use Block Gauge. (7) Do not move the Limit Switch. (8) Systemize set according to Standard Model.
51
Adjusting Waste Improvement Observation

Items Before Improvement
Manufacturing Product Height different
After Improvement
Uniform assembling height using spacer Spacer Joint Height can be uniform by using spacer
Uniform
Joint Height can be uniform by using spacer Tighten
Joint Height can be uniform by using spacer
Height
B L O C K G A U G E
Assembly Free Set Tool G a u g e M o d e l L e n g t h G a u g e
Bite Location 0 Setting Measuring Decision D L G M e o a o c c u d i a g e s t e l i i o o n n Bite Holder Tool B i t e
S T O P P E R G U I D E
Cassette Assembly Method: Model Change Time : 3 mins
Use Form Slide and insert from upper mould Slide Cassette Type
52
Attachment 2. Improvement Cases

Model Change Chart
Model Change Information Chart Operation - Model Change Information Chart Example
NO 1 Equip. Product Name 850MG Model 34D20 Change Model 34D11 Mat. HF1690 Predict Time 11:40 Mould Temp. 50C H/R Temp 220C Pre-Heat Time 10:50 End Time 11:30 PIC
Form Details
N O : Inspection Number : Record Product Name of Injection Machine : Record Product Name of Mould : Record Product Name of Model Change Mould
Equipment Name Product Model Change Model
Material : Record Material of Model Change Mould (Including Color) Predicted Time : Record Model Change Predicted Time
Mould Temperature : Record Temp. of Model Change Preparation Mould H/R Temperature Pre-Heat Time End Time P I C : Record H/R Temperature if using Hot Runner : Record Pre-Heat Time of Model Change Mould : Record Pre-Heat End Time of Model Change Mould : Record Model Change Person In Charge
53
Model Location Chart
Maintenance Using Mould Location Chart Operation Mould Location Setting Method
Main Passage
A B C
50L3
P S a i s d s e a g e
32Z10
Low Usage MOuld
Mould In Possession LIST

Code NO. 50L3 32Z10 Location Length Width A 1 B 3 No A1 B3 Product Name F/C B/C Injection Machine 1,300TON 850TON Ref.
Mould Location Chart Example
54
Model Change Actual Inspection Chart
Purpose To Measure Model Change Time of Assigned Equipment, and To Analyze Current Standard
Product : Model Change Actual Inspection Chart, Loss Time Chart

Equipment Name Station 1 Tonnes 850 T Model Change Before A D After B E 07 June 08 June A A Date Worker Time Consumed 52 mins 63 mins
Station 2 1,300 T
Form Details Equipment Name : Each Injection Machine Station Number (Ex : Station 2 etc) Tonnes : Indicate Equipment Capacity
Before Model Change : Production Model Before Model Change After Model Change D A T E Worker : Production Model After Model Change
: Actual Model Change Date of Inspection Process : Actual Worker of Inspection Process Model Change
Time Consumed : Time Consumed From Production Model's Production Completion Point to Next Production Model's Production Point
55
Model Change Loss Time Chart
Model Change Loss Time Chart Loss Rate based on Total Actual DATA Standard, Time Consume/Time Production
Equipment Name Station 2 Station 3 Station 4 Loading Time (min) 2550 mins 2720 mins 2435 mins Model Change Time(min) 450 mins 587 mins 365 mins Model Change Loss Time (%) 17.6 21.5 14.9 No. of Model Change (times) 10 times 9 times 8 times Time Consumed /times (min) 45.0 mins 65.3 mins 45.6 mins
Form Details
Equipment Name : Record Detailed Work Process per Division (Ex : PRESS Manufacturing, SMD PRINT etc) Loading Time : Equipment and Manufacturing Operation Time (Including Loss Time) Model Change Time : Sum of Time incurred during Model Change
Model Change Loss Rate(%) : Sum/Loading Time of Model Change Time() Number of Model Change : Number of Change Times Included in Model Change TIme Time Consumed/Times:Divide Model Change Time with No. of Times () After Collecting Actual Details Daily or Weekly, Create a Data System of Actual Model Change Time per Number of Times Changed of each equipment.
56
Reduce Injection Cylinder's Forward/Retreat Time Before Improvement There was no standard distance for cylinder's Forward/Retreat, and during the process of distance checking by Person In Charge, there was no location indication, resulting in excess moving time than needed After Improvement Reduced moving time by standardizing cylinder's forward/retreat distance. Maintenance by checking through stop location indication
200mm
Improvement Effect : Reduce more than 50% of Forward/Retreat Tme - Kwang Ju Vacuum Cleaner Example
Retreat/Forward Distrance (mm) Before Improve 660 480 430 660 After Improve 200 200 200 200
57
Items
Retreat/Forward Time (sec) Before Improve 48 78 41 48 After Improve 20 35 21 20
Reduction Effect
Station 1 Station 2 Station 3 Station 4
28 43 20 28
Oth. Preparation To Reduce Mould Pre-Heat Time Before Improvement Mould Pre-Heating done during In. Preparation, causing excess Model Change Time After Improvement Oth. Preparation System by Applying Mould Pre-Heat System
General Mould Hot Runner Mould
Before Improvement
Place Mould
After Improvement
Pre-Heat Mould
Connect Controller Controller
Place Mould
Temperature to rise
Waiting for Mould
Connect Controller
Injection
Injection
Wait Time:General Mould 1,312 secs(VD)
Wait Time for Temperature to Rise After Placing Mould Zero
H/R Mould 19 seconds
Improvement Effects : Mould Pre-Heat Time 1,312 secs 0 secs

58
Reduce Eye-Bolt Connect Time
Before Improvement - Eye-Bolt size differs according to mould weight so looking for the correct Eye-Bolt size during Model Change wastes time - Eye-Bolt process during In.Preparation waste time After Improvement - Standardize mould weight according to Eye-Bolt connection area and Eye-Bolt color to improve preparation waste - Preparation system for Others to improve waiting time waste [Eye-Bolt Color Standardization]
[Eye-Bolt Oth.Preparation]
Improvement Effect : Eye-Bolt Preparation Time 35 secs 15 secs (Color Standardization) 0 secs (Oth. Preparation)
59
Install Cooling Block Before Improvement Connecting each coolant hose, checking if In-Out has been properly connected took excessive time
After Improvement Reduce coolant connection time using a coolant block - Color Division to prevent error in IN/OUT installation - Apply One Touch Coupler to connect coolant block and injection machine
Improvement Effect: Cooling Host Connection Time 434secs 57secs
60
Standardize Hot Runner Connection Jack
Before Improvement By using 24 Pin, 16 Pin based on Valve and Sensor quantity, using 24 Pin caused connection preparation waste due to additional wire connections
24 PIN
16 PIN
After Improvement Simple work through standardizing Hot Runner Connection Jack Standardization of Connection Jack through Mould's Valve and Sensor Quantity Standardization
16 PIN
Improvement Effect : Common System of Spare Parts Standardization

61
Standardize Locate Ring Before Improvement Due to low protruding height, it was easy to fall off even if it was centered, and can only connect when accurately adjusted
After Improvement Through standardizing appropriate height setting for height difference per mould to reduce Location Ring Center Adjusting Time
Manufacture Taper Taper for Form Stick
Height 20mm 20mm
Improvement Effect: Locate Ring Center Adjusting Time 58s 20s
62
Improve Hoist Wire Connection Method Before Improvement After connecting Manila Roipe to Eye-Bolt, connect to Hoist hook
After Improvement Add another Hook on Manila rope to reduce Eye-Bolt and rope connecting time
Improvement Effect: Eye-Bolt and Rope Connecting Time 32s 5s

63
Install Crane Location Adjusting Indicator Before Improvement While transferring mould by crane, adjusting injection equipment center wastest time
After Improvement With mould center location indication per equipment, reduce hoist location adjusting time
During Model Change, indicate previous and next mould lowering area as per and
Additional Improvement Point During model change per equipment, differentiate previous and next mould lowering area with different color for possible additional transfer time reduction
Improvement Effect : Adjust Mould Center 47 secs 20 secs

64
Reduce Surrounding Component Dismantling Time
Before Improvement
Lots of waste factors during surrounding component dismantling such as Gas, Air, Oil Pressure Hose, Coolant Connection Area etc Various hose spread over the surrounding floor during model change
Gas Connection and Fitting Situation
After Improvement Reduce dismantling time by applying One Touch Connecting areas Providing exclusive holder for various hoses.
Improvement Effect : Gas Connection Time 98 secs 5 secs

65
Reduce Locate Ring Center Adjusting Time
Before Improvement While loading mould, locate ring center adjusting process causes Work Loss
After Improvement Find the center of Fixed Plate and make a channel to allow easy locate ring center adjustment during model change
Improvement Effect:Locate Ring Center Adjusting Time 9.2 s 2.3 s
66
Add Mould Protection Legs
Before Improvement During the process of using wooden plates to place the mould on the floor, it consumed a lot of time
After Improvement Adding mould protection legs reduced time, allowing fast mould lowering onto the floor
Improvement Effect : Mould Lowering Time 38 secs 7 secs
67
Standardize Ejector Hole Location and Size
Before Improvement Ejector Hole's location and size differed per moulds, resulting in changing the location of the Ejector Pin while replacing mould
After Improvement Erased replacing Ejector pin location work while replacing mould by standardizing the size and location of mould's Ejector Hole
Improvement Effect: Ejector Pin Replacement Time 60 secs 0 secs
68
Improve Location Ring Center Adjusting
Before Improvement During the process of lowering mould into facility, adjusting locate ring center in detail caused adjusting waste
After Improvement Create a locate ring guide line on injection machine's fixed plate
Improvement Effect : Locate Ring Adjusting Time 58 secs 30 secs
69

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Model Change Standard Manual

Ejection Model Change Standard Manual

2 Inner Check List

PIC B PIC B PIC A PIC A

Page 24 Page 25 Page 26

Check Eye-Bolt Connection Make the rope tight

Ejection Model Change Standard Manual

3. Outer Preparation Check List

Revised Date : 2006.09.11 Revised Date :

Ejection Model Change Standard Manual

PIC A Check List

2. Inner Preparation Check List

Page 31 Page 33 Page 35 Page 38

3. Outer Preparation Check List

Revised Date : 2006.09.11

Ejection Model Change Standard Manual

PIC B Check List

Page 16 Page 17 Page 18

2. Inner Preparation Check List

Page 24 Page 25 Page 27

Page 32 Page 33 Page 34 Page 35 Page 36

3. Outer Preparation Check List

Revised Date : 2006.09.11

Ejection Model Change Standard Manual

1. Definition of Model Change

2. Purpose of Model Change

3. Target of Model Change

4. Methods of Model Change

Revised Date : 2006.09.11

Ejection Model Change Standard Manual

5. Preparation for Injection Model Change Single Systemization

Revised Date : 2006.09.11

Ejection Model Change Standard Manual

6. Understanding Injection Structure

Revised Date : 2006.09.11

Ejection Model Change Standard Manual

Oil Pressure Controller

Parts Bed Form Equipment

This manual is based on 850T Valve Gate Injection Machine

. Model Change Work Order

Ejection Model Change Standard Manual

1. Model Change Standard Cycle Chart

60 mins 20 mins 10 mins

Revised Date : 2006.09.11

Ejection Model Change Standard Manual

Revised Date : 2006.09.11

Ejection Model Change Standard Manual

2. Detailed Model Change Work Standard

Oth.Prep -01 Create Current Model Change Chart

Mould Temp. 50C

H/R Temp 220C

Pre-Heat Start Time 10:50 End Time 11:30 PIC

Revised Date : 2006.09.11

Ejection Model Change Standard Manual

Move Mould to Mould Pre-Heat Area

Revised Date : 2006.09.11

Ejection Model Change Standard Manual

Mould Storage Location Indication

32Z10 Low Usage Moulds

Code NO. 50L3 32Z10

Location Length Width A 1 B 3

Product Name F/C B/C