Complex Insert Molding Applications

Dino A. Caparco

Engineering Operations Manager

Yushin America, Inc.

Complex Insert Molding Applications

• Identifying Opportunities and Evaluating Return

• Tooling Design Considerations

• Value Added Operations

• Examples of Complex Tooling

• Successful Implementation

Identifying Opportunities and Evaluating Return

• Labor Savings• Reduced operator utilization• Reduced mold open time• Semi-automatic vs. fully automatic

• Quality Consistent cycle time• Part placement for cooling• Inspection of inserts going into equipment• Proper loading and verification

• Safety • Remove operator from hazard• Ergonomics

• Internal Competencies• Current automation level• What level can you support now• Troubleshooting capabilities

Identifying Opportunities and Evaluating Return

Tooling Design Considerations

• Review with toolmaker and automation company• Design mold to be “automation friendly”

• Insert locating features

• Robot docking features

• Tooling materials• Weight constraints

• Medical or cleanroom requirements

• Material treatments

• End-of-Arm Tooling electrical requirements• Component sensors

• Communications

• Insert design• Tolerances

• Finish

• Dirt or debris

• Leads or broken edges

Value Added Operations

• In-mold inspection and verification• Avoid tool damage

• Post mold inspection • Quality control

• Inserting mold cores• Threading applications

• Electrical terminal applications

• Automatic tool change

• In-Mold labeling

• Insert Placement and

verification

• Locating Cylinders

• Docking Modules

In-Mold Labeling

• Environment impacts

functionality

• Material flow

• Label flatness

• Re-orientation of parts

• Post mold

measurement

• Individual part reject

• Insert cores with

terminals

• Post mold

continuity test

• Carbon fiber plates

for weight

reduction

• Lock and dock

• Insert Placement on

both mold halves

• Grippers to lock and

dock

• Very large product

• 21 Inserts total

• Operator loads end-of-

arm tooling direct

• Docking Modules

• Two robots working on

one part assembly

• Shuttle station to

orient parts for loading

into second mold

Semi-Automatic System

Successful Implementation

• Vendor should generate an installation plan• Identify pre-install requirements• Install support requirements

• Final Run-off • Cycle time• Uptime

• Training• Automation start-up• Recoveries• Level of authorization for operators vs. technicians

Successful Implementation

• Ensure the right people are trained on the equipment

• Become the expert on the equipment

• Work instructions for operators

• Stock spare parts for consumable items

• Error data and uptime tracking

• Systematic process for troubleshooting• Limit access to make changes• Methodical, step by step• Get to the root cause

Yushin America, Inc. – Contact Information

Dino A. CaparcoEngineering Operations Manager

Yushin America, Inc.35 Kenney Drive

Cranston, Rhode Island, 02920

USA

Telephone: (401) 490-4955

Email: dcaparco@yushin.com

www.YushinAmerica.com