SAVING COST IN 3P WAY - AIPMA
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SAVING COST IN 3P WAY KAMAL AGARWAL CEO TECHNOVATION INTERNATIONAL TECHNOVATION
Transcript of SAVING COST IN 3P WAY - AIPMA
SAVING COST IN3P WAY
KAMAL AGARWALCEO
TECHNOVATION INTERNATIONAL
TECHNOVATION
3 P’s
• PLASTICS• Material and Processing (Screw-Barrel, Die, Design)
• POWER• EFFICIENT Power Management (Motor and Heaters)
• PRODUCTIVITY• Automation (QMCs and Robots)
TECHNOVATION
TECHNOVATION
TECHNOVATION
PLASTICS
TECHNOVATION
BIMETAL SCREW BARREL
TECHNOVATION
PLASTICS
BIMETAL SCREW BARREL
TECHNOVATION
PLASTICS
POWER
TECHNOVATION
POWERTECHNOVATION
• REDUCE POWER CONSUMPTION• EFFICIENT MOTOR AND PROCESS OPTIMISATION• POWER SAVING HEATERS
POWERTECHNOVATION
• HOLDING PRESSURE• 30~60% POWER CAN BE SAVED
• COOLING• 90~100% POWER CAN BE SAVED
POWERTECHNOVATION
• MOLDING CYCLE
POWERTECHNOVATION
• Power Consumption Sheet
1. Cycle: 18sec2. = actual system pressure during motion.3. Power-consumption (KW) : average of motion as input data.
Activity Time(s) Flow(%) Pressure 80T Normal 80T ServoPower KW
POWERTECHNOVATION
• HOW
• The output flow of fixed pump is 100% all the time no matter flow requirement of each motion is different that cause the power-consumption more.
• The unused flow of each motion goes back to the oil tank according the setting pressure. All the waste power transfers into the heat that increases the oil temperature.
MotorFixed Pump
0%Flow
50%
100%
Oil Tank
Motion
SERVOMotor
GEAR Pump
50%
Flow
50%
Oil Tank
Fixed Pump
Flow
100%Motor
Motion
Oil Tank
100%
50% of power wasted
0%
50%
FULL LOAD
HALF LOAD
HALF LOAD
POWERTECHNOVATION
• Case Study – 650T
1、 Economic Benefit Analysis Power unit price 10RS./KWH 650T Before (JSW) 650T After (JSW)
Cycle Time – Sec 40 36
Injection Time – Sec 3.84 2.52
Refilling Time – Sec 12.43 12.06
Cooling Time 20 20
Motor Power Consumption 612 294
Heater Power Consumption 96 96
Total Power Consumption/day
708 390
Savings/day 318 units
Savings INR/Month Rs 95,400
Savings INR/Year Rs 11,44,800
POWERTECHNOVATION
• Case Study – 2200T
POWERTECHNOVATION
• 2200T – Car Bumper
POWERTECHNOVATION
• POWER CONSUMPTION CHART
RUNNING COST
AFTER SERVO – 0.3~0.5 UNIT/KG PF PLASTIC PROCESSING
BEFORE SERVO – 0.8~1 UNIT/KG OF PLASTIC PROCESSING
PAYBACK IS WITHIN 1-1.5 YEARS OF PRODUCTION AT 20HOURS/DAY
PRODUCTIVITY
TECHNOVATION
PRODUCTIVITYTECHNOVATION
• HYD QUICK MOLD CHANGE SYSTEMS
PRODUCTIVITYTECHNOVATION
• HYD QUICK MOLD CHANGE SYSTEMS
PRODUCTIVITYTECHNOVATION
• HYD QUICK MOLD CHANGE SYSTEMS
PRODUCTIVITYTECHNOVATION
• HYD QUICK MOLD CHANGE SYSTEMS
• QMC System allows Machine User to Clamp and Declamp Mold within few minutes by means of Hydraulic Pressure
• With the push of one Button, clamping and declamping becomes very easy and turn reduce production down time
• It provides Hydraulic and Mechanical Safety
PRODUCTIVITYTECHNOVATION
• HYD QUICK MOLD CHANGE SYSTEMS Vs TRADITIONAL CLAMPING
Traditional Way QMCS
Waste Time and Manpower Timeand Manpower can be saved by 70%
Manual Operation can result in heavyor Loose tightening of Bolts and hence cause accident
Operators can just press buttons to change mold
Bolts are usually broken QMCS sets safe Hydraulic workinpressure and interlock with the machine
Possibility of thread/Tslot damages on the platen
Only one time installation of Clamps so No possibility of damages
It needs skilled operators to change Mold
Only one General Operator can change mold
PRODUCTIVITYTECHNOVATION
• CASE STUDY - QMCS
TOSHIBA 1300TON MACHINE (ONE MOLD CHANGE EVERY DAY) JOB INCOME AS RS 1950/HR ATLEAST (RS 1.5/TON)
COST OF CLAMPS – RS 11 LAKH APPROXPRODUCTION DOWNTIME SAVING – 90 MINS (FOR 1 MOLD)PRODUCTIVITY INCREASED – 90 MINS INCOME INCREASED – RS 2925/DAY I.E. RS 87,750/MONTHBREAK EVEN ACHIEVED IN NEARLY 1 YEAR 1 MONTH.
AFTER BREAK EVEN EVERY MONTH EXTRA INCOME IS RS 87,750AND WE HAVE NOT INCLUDED THE SAVING OF ONE OPERATOR
PRODUCTIVITYTECHNOVATION
• Video Comparisions
PRODUCTIVITYTECHNOVATION
• Auto Slide QMCS Video
Check Points to AskTECHNOVATION
• Which BiMetal Coating on Screw and Barrel?• For upto 40% Glass, It must be WC 30%• For Transparent Material, It must be Chrome Plated
• What is the Power Cost per KG of Material Processed?• It should not be more than 0.5 Unit/KG• Ideally should be 0.3 Unit/Kg
• How Much time consumed in one Die Change?• If Consuming more than 10 Min, Think of QMC
• How Much is Operator Take Out Time?• If more than 4 sec, Consider for Robots
ContactTECHNOVATION
• KAMAL AGARWALCEOTECHNOVATION [email protected] : 9910178880
WORKS : PLOT NO 11, NEPCO COMPOUND, 20/4, MATHURAROAD, FARIDABAD, HARYANA
REGD OFFICE : EXCEL 502, IMPERIAL ESTATE, SECTOR 82FARIDABAD, HARYANA
THANKS
QUESTIONS PLEASE
TECHNOVATION
