Selection

The ARBURG Magazine

MASTHEADCONTENT Selection Service 07/2010

Fast set-up times – efficient productionAn individual approach to technology training!Retrofitting energy-efficiency?A sure eye for maintenanceTotal accessAssuring qualityOnly ARBURG service is originalOil management counts Machine inspection and certificationActive spare parts managementStrong togetherSmooth runningService around the clock

- Issue 43- Issue 43- Issue 42- Issue 42- Issue 33- Issue 37- Issue 38- Issue 37- Issue 30- Issue 29- Issue 28- Issue 32- Issue 25

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Service

today, the ARBURG magazineReprints, including excerpts, may be made with permission only.Responsible: Matthias UhlEditorial advisory board: Oliver Giesen, Juliane Hehl, Martin Hoyer, Herbert Kraibühler, Bernd Schmid, Jürgen Schray, Wolfgang Umbrecht, Renate WürthEditorial team: Uwe Becker (text), Markus Mertmann (photos), Susanne Palm (text), Oliver Schäfer (text), Vesna Sertić (photos), Peter Zipfel (layout)Editorial address: ARBURG GmbH + Co KG, PO box 1109, 72286 Lossburg, GermanyTel.: +49 (0) 7446 33-3149, Fax: +49 (0) 7446 33-3413e-mail: today_kundenmagazin@arburg.com, www.arburg.com

2 today 43/2010

TECH TALK

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Dipl. Ing. (BA) Oliver Schäfer, Technical Information

Small series, different product versions, just-in-time produc-tion and delivery, these are the

requirements which increasingly face injection moulding companies. These result in frequent changeover proce-dures, when machines stand idle and fail to return a profit, even though they continue to consume energy. Time literally becomes money. In or-der to produce flexibly, energy-effi-ciently and competitively, short set-up times are essential. This can often be achieved without major investment.

Perfect preparation as the previous job is still running is of crucial importance for a fast changeover. Checklists help ensure that nothing, for example the appropriate hoses, is forgotten. In addition, a well-or-ganised cart with all the required tools and bolts should be available prior to every set-up. This means that everything is in place as soon as the machine stops. Nothing needs to be searched for or fetched. Af-ter all, every unnecessary journey wastes time.

A decisive time factor during the changeover procedure is the actual chang-ing of the moulds, particularly in the case of larger machines. Distances, and there-fore the time expended, can be reduced

significantly by placing one technician at the front and one at the rear of the ma-chine. This applies particularly if you con-sider how often a single technician has to walk around the machine during the set-up procedure (see diagram).

A standardised clamping system should be chosen when designing the tools. It is important that the clamping platens are of the same size when the moulds are mount-ed directly. This allows you to use the same

bolts throughout. Work can be made even easier by using clamping elements that re-main attached to the machine and that can be used flexibly for other moulds. If a large number of in-house moulds are used, it is advisable to standardise the clamping platens. In combination with mechanical rapid clamping systems such as the one provided by ARBURG, moulds can be changed in just a few minutes. Ide-ally, a power-adapted temperature control

Fast set-up times – efficient production

Servicing Mould

Material box

Tool cart

Fetch hose

Machine cabinet

Total: 701 m

Source: Fischer Consulting

Quality assurance

4 x 10 m 4 x 40 m 4 x 3 m

5 x 14 m

6 x 2 m

4 x 5 m9 x 4 m

5 x 7 m

14 x 2 m4 x 40 m4 x 4 m

18 x 6 m

6 x 3m

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3today 43/2010

unit should be permanently assigned to a machine so that set-up can be performed in a straightforward manner in conjunc tion with standard rapid connect couplings.

The next step in increasing efficiency is the standardisation of the entire set-up process. After all, in the absence of a precisely defined, systematic set-up procedure, every employee will deter-mine his own. In this case, optimisation often becomes a secondary concern. If, on the other hand, all employees follow the same standard, frequently practising and improving it, machine downtimes can be significantly minimised. Employee training is particularly important. After all, this measure will help in implement-ing speedy set-ups more effectively than any investment. In many cases, the in-tensive involvement of employees also brings about an increase in innovations, resulting in a continuous improvement process.

Forward-thinking, machine-based production planning is essential if instal-lation technicians are to organise their work to optimum effect and achieve short set-up times. Production manage-ment systems with online entry of ma-chine and order data such as the ARBURG host computer system (ALS) ensure the necessary transparency in production

and facilitate detailed planning on the basis of current, reliable data.

Further measures aimed at reducing set-up times include the use of a pre-heating station for moulds and the pro-vision of several cylinder modules. The advantage of the latter when changing colours to a completely transparent ma-terial is that the sometimes very time-consuming cleaning work can be omit-ted.

ARBURG has always worked to keep set-up processes as simple as possi-ble. This is demonstrated by several ALLROUNDER features such as the ejec-tor rapid release coupling, media con-nectors positioned on the machine’s clamping platens, swivelling injection units, central coupling of the cylinder module and the second program level of the SELOGICA control system.

If one considers the many opportuni-ties for optimising the set-up process, there is still a lot of untapped potential in many injection moulding companies. Experience shows set-up time reductions of up to 50 percent are not unusual.

Investigations have revealed that the

distances travelled during set-up can

sometimes be considerable

(see graphic on left). Minimising

these distances represents a

key step in reducing

set-up times

Fast set-up times – efficient production

4 today 43/2010

Again and again, surveys and statistics confirm what we have already known for some

time in Germany and Europe: We live and work in a high-wage region and must take appropriate steps to ensure our international competitiveness. Consequently, automated production cells are increasingly being used in plastics processing in order to produce cost-effectively in large-volumes.

For this purpose, complex machine and control system technologies are required whose potential must be exploited in full in order to achieve consistent quality and efficiency. To this end, ARBURG is offer-ing individually tailored training programs held directly at the customer’s premises. Offenau-based company KWO has made extremely positive experiences with this offering to date.

Since the management buy-in in 2005, Kunststoffteile GmbH Offenau has been managed by Dr. Michael Jauss and Matth-ias Wendler as owners. The development of the company, which Matthias Wendler describes as an “organic growth of 60 per-cent between 2005 and 2008”, has seen sales rise to 16 million euros in 2008. At its location in Offenau near Heilbronn, KWO deals in the manufacture of moulds and

high-volume part produc-tion. 80 percent of pro-duction is accounted for by the automotive sector, with a further 20 percent in the consumer products sector. The company’s customers are locat-ed in Germany, Hungary, Czech Republic, France, Belgium, Switzerland and the UK. “KWO intends further expansion in the fu-ture,” says Wendler. “At present we have a production area of 3,000 square metres and we already have building permission for a further 1,500 square metres.”

The production halls house a total of 40 injection moulding machines, 30 of which are from ARBURG. These include both ro-tary table machines and electrical and hy-draulic ALLROUNDERs, some of which are equipped with corresponding MULTILIFT robotic systems. Wendler assesses the co-operative relationship between KWO and ARBURG, which has existed since 1981 when the company first began injection moulding production, as being good and reliable: “Pricing and scheduling are rea-sonable and response times are pleasantly short. Injection moulding machines and robotic systems can be integrated very suc-cessfully in our production environment. We see great promise in the technology used in the ARBURG host computer sys-

tem ALS and will soon intro-duce this. Naturally, repairs to injection moulding ma-chines are an ongoing issue and are always a problem. However, this is not some-

thing that solely affects ARBURG.” Because all ALLROUNDER machines

are equipped with the universal high- performance SELOGICA machine con-trol system, it quickly became clear that it would make sense to provide employ-ees with in-depth training on making the best use of all the options provided by this control system and consequently of the machine technology as a whole. ARBURG therefore devised an individually tailored two-year training package for KWO that would each month focus on the challenges currently faced by the company and deal with them in terms of the control system and injection moulding technology.

The training days begin with a discus-sion on pending issues at the manage-ment level. Depending on requirements, the installation technicians who are to receive the individual training also attend. The focus is mainly on general issues relat-ing to machine and control system tech-nology. Among the issues discussed are the possibilities in relation to forthcoming operational projects with ALLROUNDERs

An individual approach to technology training!

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and the options required in order to meet these requirements.

Following the meeting, the training moves into production, where the agreed agenda is gone through with the relevant training course participants and the available procedures and options with regard to the machine and control system are explained. The day ends with a final meeting in which the achieved results are discussed.

As the course progresses, all the proc-ess engineers thus receive at least one day of intensive “on the job” training. Mat-thias Wendler believes that this training is

extremely important: “We consider this training crucial in order to exploit the full potential of ARBURG machines in practice in our company. Following the conclusion of the first year of training, we were proven right in our opinion that these courses were worthwhile, particularly in terms of the qual-ity of parts production and the efficiencies achieved.” And how do the trained employ-ees view the program at the half-way point? The answer could hardly be more concise or decisive: “Excellent!”

Owner Matthias Wendler (centre) is

delighted with the success of the ARBURG

training courses, performed directly on

the ALLROUNDERs (right). Detailed

discussions (left) ensure that the

contents are perfectly tailored to

KWO production.

INFOBOX

Founded: 1971, 2005 management buy-inProducts: Engineering, moulds and parts, in particular high-precision parts, such as connectors for control system electronics, micro injection moulded parts, LSR two-component parts and complex assemblies made from PA, PBT, PPA, PPS, LSR, LCP, TPE, PC, PPQuality assurance: ISO 9001, TS 16929, ISO 14001/EMAS in the first quarter of 2010Employees: 140Contact: KWO Kunststoffteile GmbH Talweg 9 - 13, 74254 Offenau, Germanywww.kwo-kunststoffteile.de

An individual approach to technology training!

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Dipl. Ing. (BA) Oliver Schäfer, Technical Information

TECH TALK

Energy-efficiency is currently a much-debated topic, for in-jection moulding companies

as well. As an innovative injection moulding machinery manufacturer and pioneer with regard to energy ef-ficiency, ARBURG is confronted with an ever growing number of enquiries on a daily basis. In addition to select-ing the right machine concept for new purchases, there is now increasing focus on retrofitting energy-efficient technology on older injection mould-ing machines.

However, in many cases, the potential for energy savings achievable through retrofitting is insufficient to warrant the sometimes extremely high conversion costs. This applies especially to small and medium-sized injection moulding ma-chines. The reason is that the energy re-quirements and therefore the potential for savings decrease the smaller the machines are (see chart). In contrast, retrofit and conversion costs are largely independent of the machine size.

Examples of this are the retrofitting of an electric dosage drive or speed control-led pump motor on hydraulic machines - regulating pumps have been the stand-ard in ALLROUNDERs for over 30 years. During conversion, the control system and software must also be upgraded. This en-

tails not only the considerable cost of new components such as frequency converters and motors, but also the associated labour costs. Owing to the high conversion costs, these retrofitting measures are therefore seldom economically viable. The situation is quite different if the energy-efficient equip-ment is ordered directly when the in jection moulding machine is purchased. In this case, the higher investment costs incurred are significantly reduced due to the absence of the conventional components.

The same applies to the retrofitting of

energy saving motors of the highest ef-ficiency class, EFF1. In comparison with a conventional EFF2 motor, energy savings of up to four percent can be achieved, but the greater energy-efficiency alone is not sufficient to justify the replacement of ex-isting motors. However, if a faulty motor needs repairing or replacing, it may cer-tainly be worth considering the alternative EFF1 motor. The available installation space is also decisive because energy-saving mo-tors are larger than EFF2 motors.

A further retrofitting option is to fully

Retrofitting energy-efficiency?

Machine size

Cos

t sa

ving

s / y

ear

Basis for calculation: typically equipped machi-nes with half material throughput at 6,000 operating hours per year and an electricity price of € 0.12.

Electric dosage driveSpeed-regulated pump motor

4000

3000

2000

1000

0270 370 470 570 630 720 820 920

EFF1 pump motorFully insulated cylinder module

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insulate the cylinder module of the in-jection unit. This allows the heat dissipa-tion losses to be reduced to a minimum. However, all insulation also represents an intervention in temperature control and must consequently be designed with the relevant application in mind. The viscosity of the processed material and the material throughput play a decisive role here. De-spite all considerations with regard to ef-ficiency, however, a controlled, reproduc-ible process must always be the priority. A compromise between energy saving and process stability is the standard insulation of the cylinder modules on ALLROUNDERs. Heat loss through radiation is already sig-nificantly reduced, while at the same time ensuring a more controlled, more repro-ducible process. Nevertheless, it is always recommendable to consider the option of full insulation.

Additional potential is said to be achiev-able through decentralised reactive cur-rent compensation directly at the injec-tion moulding machine. However, most injection moulding businesses already use centralised reactive current compensation systems. These are generally more than adequate.

The currently available low-viscosity multigrade hydraulic oils also generally permit energy savings. The extent of the potential savings on a particular machine, however, ultimately depends on a number

of influencing factors, for example the injection moulding process and the type of hydraulic drive. Consequently, only an individual comparison generally proves meaningful. The energy savings achieved by means of low-viscosity hydraulic oils must be balanced against higher purchas-ing costs and, in the case of retrofits, the costs for changing the oil in the injection moulding machines. Bear in mind, how-ever, that the use of these hydraulic oils is not always permissible on account of their low viscosity, particularly in the case of older pump systems.

The examples described show that the retrofitting of already installed injec-tion moulding machines for the purposes of energy efficiency is a complex task which often fails to live up to expecta-tions. However, the potential for energy savings in production organisation is of-ten completely neglected. This is despite the fact that such measures can usually be implemented directly without any ad-ditional costs. A good example of this is standby mode. This standard function of the SELOGICA control system means that you can help save energy by simply press-ing a button, for example during breaks or downtimes. Whether standby mode only involves switching off the pump mo-tor or whether cylinder and mould heat-ing are lowered can be easily programmed in accordance with the moulds being

used. Another interesting feature of the SELOGICA is the automatic switchover to standby mode if the control system does not register machine movements during a freely programmable period. Training and awareness-raising of employees should therefore always be a central component of energy efficiency activities.

Energy efficiency: switch-on to

switching-off (top). The energy-saving

potential of retrofitting measures (chart on left),

however, is often insufficient to justify

the conversion costs.

Retrofitting energy-efficiency?

8 today 42/2009

Selection

A prerequisite for the perma-nent availability and reliabil-ity of an injection moulding

machine is careful and regular main-tenance. To ensure that nothing is left to chance during routine production, the SELOGICA ‘direct’ machine con-trol system features a user-friendly maintenance program - including con-tinuous monitoring of due dates and automatic reminders for forthcoming maintenance work.

Depending on the configuration of the relevant ALLROUNDER, all the neces-sary maintenance tasks and intervals are already specified in the control system in plain text form. As an option, further indi-vidual maintenance specifications, relating for example to moulds or additional pe-ripherals, can be entered manually. Finally, the SELOGICA can be used to generate a clear maintenance plan for the entire pro-duction unit, which always provides infor-mation on when the various maintenance tasks are due.

The due date for the recorded main-tenance work is continuously checked according to operating hours, machine cycles or months. A separately adjustable early warning threshold also provides in-formation about pending maintenance tasks, ensuring optimum planning and preparations.

If a maintenance interval is accidentally exceeded, the machine does not stop im-mediately, but continues to operate until the batch has been completed or until the next manual stop. However, in order to re-start the machine, the correct completion

of the pending maintenance work must be confirmed in the SELOGICA system. The control system logs and saves every acknowledgement in a so-called mainte-nance log. As a result, every maintenance completed remains fully transparent, also providing ideal verification for audits and certifications.

In principle, all standard maintenance tasks on ALLROUNDERs can be carried out by the operator himself in accordance with the operating manual. With inspection contracts, however, all important machine elements are inspected for wear, operabil-ity and safety by an ARBURG service tech-nician on a regular basis. From October 2009 onwards, ARBURG will also provide training courses on “Preventive Mainte-nance”. These courses can also be tailored to the needs of individual customers and provided on their premises. A customer-specific training course of this type makes it possible to combine injection moulding

theory and practice to optimum effect, and to directly exploit the resulting poten-tial for improvement.

A sure eye for maintenance

You will find all maintenance-related

information in a clearly-organised

overview on the relevant SELOGICA

screen pages.

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Total access

The production volumes are get-ting smaller, the deadline con-straints are becoming tighter:

in order to meet these demands, the capacity and flexibility of the machine fleet must be optimally utilised. This is where the ARBURG Remote Service (ARS) software comes in, which ena-bles remote access to the control sys-tems of the ALLROUNDERs via PC.

With ARS, the production time and ma-chine downtime of the ALLROUNDERs can be monitored. Akin to a tachograph, the ARS records the machine status and dis-plays it clearly in chronological sequence. For instance, the production sequence during a shift can easily be analysed.

Based on current machine and pro-duction data, it is possible to determine via ARS, which jobs are running on the machines and to what extent these have been completed. The progress of produc-tion can be monitored transparently at a glance for production planning purposes. In order to react quickly to impending deadline violations, ARS also enables the transfer of machine programmes from one machine to another.

A further feature is the option to dis-play and print out individual screen pages. The current production process can thus be analysed and documented at all times. Consequently, a centralised user support

system including remote diagnosis or re-mote maintenance via ARBURG Customer Service can be provided. For protection of the production data, it can be determined explicitly which users have access to what machine via the ARS user and machine management system.

When setting up an ARS, the interna-tionally recognised Ethernet networking standard is employed, which is also used for PC networking. For connection of an ALLROUNDER to the network, it must be equipped with the ALLROUNDER@web machine interface. The ARS software is installed on the central PC in the network. Machine and production data can then be accessed from any other PC connected to the network. Remote production locations or facilities can also be accessed via exist-ing network connections so that produc-tion there can be monitored at the click of a button.

The performance of ARS can be tested using the demo version at http://demo.arburg.com/ars.

In addition to ARS, ARBURG also offers its customers the ARBURG host computer system (ALS), the functionalities of which extend far beyond those of the ARBURG Remote Service. The ALS basic module for machine and operating data record-ing can be flexibly adapted to the specific operating requirements through mutually-compatible expansion modules. The func-tionalities of ALS can thus be expanded far beyond the conventional BDE or MES sys-tems. Even connection to production plan-ning systems (PPS or ERP) can be realised.

Remote access to the ALLROUNDER

screen pages (centre) is possible via ARS

and the ALLROUNDER@web machine

interface (above right).

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Capability validation serves to assess machines and produc-tion processes with regard to

quality considerations. But in the field of injection moulding, in particular, opinions can differ widely as to what machine and process capability ulti-mately mean. Clear definitions are therefore vital for all concerned.

The quality capability of an injection moulding machine depends primarily on the precise operation of its measurement and control systems. This can be ensured through the calibration of all quality-rele-vant machine parameters during dry runs, i.e. operation without mould or material. Calibration of this type is performed on every ALLROUNDER prior to delivery. How-ever, because machine parameters may change over time, for example through wear, regular re-calibration is necessary.

Only in this way can the reproducibility of an injection moulding machine be main-tained. ARBURG offers inspection con-tracts for this purpose.

A quality-capable injection moulding machine is the first prerequisite for ensur-ing moulded part quality. But parameter settings, the mould, cooling, temperature control as well as the material, operator and environmental conditions also have an influence on moulded part quality. In order to prove the process capability of an injection moulding machine, moulded parts must therefore also be produced and specified characteristics and toler-ances checked.

Process capability is divided into two stages, depending on the environmen-tal conditions and the timeframe of the investigation. The first stage is so-called short-term capability, in which only a small number of consecutively produced mould-ed parts are examined. Due to the short testing period, influences owing to ma-terial, operator and environment remain virtually constant. The result therefore permits a basic statement on the quality capability of the production facility and is consequently referred to as ‘machine capability’. Machine capability is usually verified during acceptance testing at the factory using the customer’s mould and materials. If customers so wish, ARBURG can provide assistance in the determina-

tion of tolerances and the statistical analy-sis of individual process parameters.

Statements on the actual process ca-pability, however, can only be made once quality capability is examined under real process conditions. Tests of this kind must necessarily be performed on site and over an extended period, so that influencing factors such as the material, operator and environment can take effect. Here, the ARBURG quality assurance system AQS can provide assistance.

Assuring qualityThe calibration of injection moulding

machines is based on guidelines

produced by the VDMA (German

Engineering Federation).

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What applies to ARBURG’s machines and spare parts applies equally to the

company’s entire range of services: customers are only covered by a full warranty if their ALLROUNDER injec-tion moulding technology is serviced by ARBURG specialists. You don’t hand your car to your neighbour for an MOT, do you? You go to an author-ised, specialist repair shop.

Even if you’ve read otherwise else-where, you can only get original ARBURG service from ARBURG. For of course, ARBURG cannot take responsibility for work carried out on ALLROUNDERs by un-authorised third parties. This applies both to the parts used and the service itself. But not only can inexpert repairs cause

warranty claims to become invalid, they can have much worse con-sequences - such as machine fail-ure. In that case, rapid assistance from ARBURG specialists cannot necessarily be taken for granted,

for if service work has been hand-ed over to third parties, then of

course the service documentation supplied with every machine will be

incomplete. And as a result, there may be problems with the hotline service and machine calibrations, incorrect diagnoses may be made or the wrong parts deliv-ered. In other words, it may simply take longer to locate the fault and remedy it in the proper manner.

Basically, the road to inexpert services is extremely easy, which makes it all the more problematic: independent engineers and service technicians have not benefited from ARBURG’s training in the latest injec-tion moulding technologies and therefore cannot possibly possess the solid expertise of ARBURG specialists. So, getting repairs done in this way always entails a risk.

For this reason, for all ARBURG custom-ers it really matters to whom they contract their services. For what seems cheaper at first can ultimately turn out to be an expensive mistake.

On the other hand, customers who work not just with the ALLROUNDERs but also with ARBURG’s expert service can access and place their trust in an exten-

sive range of services. Our offer ranges from a 24-hour hotline to in-depth train-ing courses on machines and technology, preventive maintenance via service con-tracts, our oil service, a comprehensive spare parts service, technical advice and finally, the rapid handling of all warranty claims. In this area, too, ARBURG’s good reputation didn’t come about by chance. ARBURG offers Service allround - and in the long term, that always pays off!

If you want perfect maintenance and

repairs and high machine availability, it’s

best to rely on ARBURG service.

Only ARBURG service is original

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12 today 37/2008

In addition to improper mainte-nance, contaminated hydraulic oil is one of the principal causes of

faults in injection moulding machines. In 70 to 90 per cent of cases, damage to hydraulic components is attribut-able to contamination in the hydraulic system. The goal of oil management is to prevent contamination of this kind in order to enhance the availably, reli-ability and therefore the efficiency of injection moulding machines. Oil man-agement is not restricted to the end user, it also involves the manufacturer of the injection moulding machine.

Hydraulic oils can become contami-nated through air, water or solid particles. It is contamination by solid matter that is the primary cause of significant surface damage to hydraulic components through wear mechanisms such as abrasion. The consequences are control inaccuracies, leaks, losses in efficiency and a shorter service life of components. More and more particles penetrate into the hydrau-lic oil and wear is further increased. Even filter systems can only interrupt this chain reaction of wear to a limited extent. In addition to the number of particles, their size also has a decisive influ-ence on wear. The wear-induc-ing particles are so small that they cannot be detected by the naked eye.

In order to achieve a repro-ducible classification of particu-late contamination in hydraulic oils, several standardised methods of analysis are available. The international

Oil management counts

13today 37/2008

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Oil management counts

ISO 4406:1999 standard is widely used, in which the number of particles larger than four, six and fourteen microns respectively is determined and assigned to a defined characteristic value. In practice, automatic particle counters are normally used for this purpose. The purity of a hydraulic oil can thus be assessed very quickly and simply. It should be noted that the increase of a characteristic value by a factor of one represents a doubling of the number of particles.

But how do hydraulic oils become con-taminated in the first place? First of all, a lack of cleanliness with regard to compo-nents during assembly is worthy of men-tion. This so-called original or initial con-tamination of the hydraulic system can have a decisive effect on the reliability of an injection moulding machine. As a rule, the lower the degree of original contami-

nation, the more wear-free the hydrau-lic system will initially be. Consequently, oil management always begins with the manufacturer.

A further important source of con-tamination is the hydraulic oil itself. The required purity class of the oil is de-termined by the hydraulic system: The higher the performance requirement of the parts used, the greater the demands. ALLROUNDERs require purity class ISO 18/15/12. Conventional drum oil does not meet this standard.

The seriousness with which ARBURG regards the subject of oil management can be seen in all areas of production. Prior to assembly, for example, cast parts such as the housing or cylinder covers are freed of soiling in so-called “washing machines”. Once cleaned, all the compo-nents are kept in closed boxes or under protective film until they are installed. A similar procedure applies to the hydraulic pipes and hoses, which are rinsed out and then protected from soiling by means of plugs. ARBURG also commissions all the injection moulding machines before they leave the factory. The purity class of the hydraulic oil used for this purpose is regu-larly monitored and is significantly above the requirements. The oil tank is vacuum evacuated following commissioning.

All these efforts on the part of ARBURG would however be nullified without the end user’s co-operation. For example, if hydraulic oils that do not comply with the specified purity class are used in ALLROUNDER machines. Proper storage of the hydraulic oils is decisive in order to maintain their purity class. Hy-draulic oils should also always be filled via a micro-filter unit. If these measures

are not observed, contamination of the hydraulic system will automatically occur. In this case, preliminary damage and even the premature failure of hydraulic com-ponents is virtually pre-programmed. The final step in effective oil management is the regular performance of oil condition analyses. These permit the reliable detec-tion of unusual contamination of the hy-draulic oil. Conclusions can therefore be drawn with regard to wear on pumps and seals, for example.

Cleanliness is a priority at ARBURG: for example,

components are kept in closed boxes until assem-

bly (photo, top left), and the oil tank is vacuum

evacuated prior to delivery (photo, top right).

The oil tank should always be filled via micro-filter

units (photo, centre). Microscopic photographs

(bottom left: Pall Corporation) clearly demonstrate

the differences in quality of hydraulic oils

(ISO 18/15/12 and 21/20/17).

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At the Fakuma 2003, the service

department had its own presen -

tation forum within the ARBURG

stand (above). Among other items to be

presented here in 2005 will be the new

inspection contracts (right).

pressure inside the mould as well as the temperature measurement chain inside the cylinder and also in the mould, cali-bration of auxiliary control valves, a gen-eral inspection, a check of the protective guards and also an oil analysis by an in-dependent laboratory. Approval tests can also be performed at the factory for new machines.

These inspections can be performed in intervals of one or two years, depend-ing on the requirements of the custom-er. The customer then receives updated digital documentation for each inspect-

ed machine, in which the results and measured values for up to five inspec-tions are logged and documented in de-tail. Within the scope of certification, for instance, this can serve as proof of pre-ventive maintenance. In future, custom-ers will also receive an official ARBURG inspection certificate as well as inspec-tion badges for each machine.

In order to further illustrate the in-spection process for visitors at the Faku-ma, a service technician will explain the various inspections and measurements live on an ALLROUNDER 170 U.

In addition to the machine exhibits at the Fakuma, ARBURG will also be presenting its complete range

of services at its stand-in-stand. The new inspection contracts, which in-clude a certificate and an inspection stamp of approval, are the focus of our technical service. Thanks to the modular structure of the service, the inspection intervals and the scope of inspection can be determined individ-ually according to the requirements of the customer.

Because inspection plays an impor-tant role in many certification processes, ARBURG has been offering its custom-ers inspection contracts for a number of years now. As outlined in these contracts, ARBURG service technicians check all key elements of the machine for wear, correct function and safety at defined intervals. This also includes the inspection and, if necessary, recalibration of all machine and control parameters that relate to quality.

In order to offer its customers tailor-made solutions that meet a variety of quality standards, the new inspection con-tracts are designed in a modular format.

The basic inspection includes the cali-bration of parameters relevant to the in-jection moulding process and can also in-clude the recording of actual values as an option. Additional options include an eval-uation of displacement measurements, an inspection of the mould platens for paral-lel alignment, with or without recording actual values in each case, testing the

Machine inspectionand certification

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Active spare parts management

Well attended - the “Service“ presen-

tation forum set up especially for the

Technology Days.

Personalised customer sup-port has been high priority at ARBURG for a great many years.

This has been further enhanced by the introduction of active spare parts management (ASM). This includes ex-tensive consultancy services, a high level of spare part quality and avail-ability with a fair price/performance ratio, as well as customised mainte-nance and expendable parts pack-ages.

The aim of ASM is to reduce downtimes and therefore costs by means of proactive planning.

An important factor is extensive, personalised consulting. Depending on the machines used and the materials to be processed, ARBURG sup-ports its customers with advice and assistance and helps them select the suitable com-ponents. In this way it is often possible to rule out production problems from the

outset. In order to minimise production downtimes, various maintenance and ex-pendable parts packages are put together for the customers, which are tailor-made to the relevant machine fleet. An impor-tant aspect of this is the guarantee of be-ing able to subsequently purchase spare parts for older machines.

The high degree of spare part quality and availability is ensured by the in-house production at the headquarters in Loss-burg – from development to series pro-duction. Thanks to constant investment

in modern production facilities and processes, ARBURG is able to of-fer quality products with the best possible price/performance ratio. The costs, for instance, of complete cylinder mod-ules and of individual screws and cylinders have been considerably reduced through opti-

mised screw production processes. Those wishing to achieve additional cost sav-ings can procure spare parts packages at

favourable conditions. Furthermore, the high degree of spare parts availability in conjunction with a sophisticated in-house logistics system guarantees fast shipment of spare parts.

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16 today 28/2005

Selection

Two target groups – one target: Both customers and ARBURG service en-gineers alike make use of training

courses to familiarise themselves with the details of the ARBURG products and to enhance their knowledge of injection moulding. Combining training for custom-ers and internal service engineers under one roof seemed the most logical conse-quence. And this is exactly what ARBURG did some time ago by assigning both train-ing schemes to the new Product Training department.

At first glance, merging customer training and internal service-engineer training might not appear to have changed much. However, a look behind the scenes quickly reveals the deci-sive advantages of this approach.

Uwe Klumpp is the central contact person responsible for co-ordination of the entire training department. As there are experts with many years of practical experience working in customer training as well as in service-engineer training, they can now be deployed flexibly and effectively in both departments. Response to customer‘s requirements is quick, and specially

tailored courses can also, for example, be pro-vided at the customer‘s premises.

As a result of the expansion of the Product Training department, the team now numbers 17, – and rising. The group of 14 instructors in-cludes plastics engineers and process engineer-ing technicians for plastics and rubber tech-nologies, from mechanical engineers through to electrical engineers and technicians. The entire spectrum of injection-moulding technol-ogy is thus covered by appropriate specialists, including the areas of rotary table machines, multi-component injection moulding, powder injection moulding, thermoset processing and the ARBURG host computer system (ALS). In terms of machinery and robotic systems, the team in Lossburg is very well equipped with various ALLROUNDERs and MULTILIFT robotic systems which are available exclusively for training purposes.

In order to ensure that all the ARBURG service engineers around the world are highly trained and possess in-depth expertise in the areas of injection moulding technology and ALLROUNDER technology, they all undergo standardised training in Lossburg. This also benefits the customers who receive the same

Strong together

comprehensive knowledge relating to the ARBURG products when they attend training courses. The advantages of the joint Product Training department are also evident with re-gard to new products, as the service techni-cians receive early training on them. Thanks to standardised training documentation, com-piled by the instructors and later to be made available in digital, animated form, the range of customer training courses on offer can be extended very quickly.

The “Product Training“ team around Uwe Klumpp

(front right) is made up of experts from a

variety of fields, who train the internal

service engineers as well as customers

on all ARBURG products.

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17today 32/2006

Selection

Today, increased productivity plays a significant role when it comes to competitiveness and

cost savings. For this reason, many injection moulding companies are investing in increasingly complex production facilities. However, costly investments only pay when these fa-cilities have a high rate of availability. A prerequisite for the permanent availability and reliability of an injec-tion moulding machine is careful and efficient maintenance.

Unscheduled stoppages and the result-ing machine downtimes not only result in considerable costs, they also upset the en-tire production planning. Delivery delays, penalties for non-fulfilment of contracts and dissatisfied customers are the pos-sible consequences. Occupational safety aspects are a further reason for regular maintenance. When resolving liability issues in the event of accidents, it can be crucial that safety-relevant maintenance work has been properly carried out.

Wear is a natural, unavoidable proc-ess in the case of injection moulding machines. For instance, rubber materials such as hoses and seals age, even without direct use.

The longest possible uptime is essential in ensuring economical production. The main purpose of preventive maintenance is to maximise the uptime by minimising wear. Through regular maintenance, wear can be controlled, necessary repairs can be detected in a timely manner and can consequently be planned. Possible faults, downtime and consequential damage can thus be prevented. The availability, reliability and therefore the efficiency of the injection moulding machine increases. Simultaneously, an excessive diminution

in value of plant equipment is prevented. A further objective of preventive mainte-nance is ensuring safe working at the in-jection moulding machine.

A significant benefit of prevention is the reliable planning of the maintenance and repair measures. Repairs can be car-ried out at the “most favourable” time.

The basis for the inspection, lubrication and replacement intervals is the mainte-nance schedule contained in the operating instructions. Through careful documenta-tion, the costs to be incurred can also be reliably allowed for.

Important aid: Computer-assisted planning and documentation of mainte-nance and repair activities for machines and moulds can be performed using the ARBURG ALS host computer system.

Moreover, ARBURG offers its customers the option of having all important machine elements inspected for wear, operability and safety on a regular basis by a service technician within the scope of an inspec-tion contract. Our Service personnel will be pleased to answer any further queries: service_germany@arburg.com

Smooth running

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18 today 25/2004

Radevormwald

Worms

Neustadt

Rednitzhembach

Berlin

Bremen

DresdenErfurt

Frankfurt am Main

Hamburg

Hannover

Kiel

Köln

Leipzig

Nürnberg

Rostock

Stuttgart

LossburgFreiburg

München

Selection

Service around the clock

ARBURG Service Allround - this is the extended range of ARBURG services available to the Ger-

man market as of January 2004. It not only provides a hotline for telephone support around the clock, but in an emergency, service engineers can be requested even at weekends or on public holidays.

Traditionally, a comprehensive and cus-tomer-orientated range of services has always been high on ARBURG‘s agenda and list of priorities. We constantly work to meet the challenges of the future head-on. The most

recent result of this is the extended serv-ice range available to the German market, “ARBURG Service Allround“. It consists of a hotline which is available 24/7 and a callout service for service engineers at weekends and on public holidays.

However, the new range of services re-quired a structural cha- nge in the field of serv-ice. So that nothing was left to chance when implementing the serv-ice, it has undergone extensive testing at the service location Neus-tadt near Hanover since

early 2002. Only after a successful trial run, were further Service Centres set up at the headquarters in Lossburg, at the ARBURG Technology Centre in Rednitzhembach, at the ARBURG Info Centre in Radevormwald and in Worms.

Customers can reach their regional contacts at all five locations free of charge on week-days between 7 AM and 5 PM for all service enquiries. In addition, an “expanded“ paying hotline is available, which is operated by quali-fied ARBURG employees between 5 PM and 7 AM as well as around the clock at weekends and on public holidays. Their workstations are connected online to the ARBURG headquar-

ters and the Service Centres so that they have access to all important customer information and machine data and equipment, and can provide comprehensive support.

In urgent cases where it is indispensable that the fault be remedied at the weekend or on a public holiday, a service engineer can be requested using the expanded hotline. For these chargeable emergencies, a service en-gineer will be on standby duty in each service area and will come to your location between 8 AM and 2 PM.

INFOBOX

The Service Centres can be reached free of charge on weekdays between 7 AM and 5 PM:Lossburg: 07446 33-39 09Neustadt: 05036 802Radevormwald: 02195 50 40Rednitzhembach: 09122 792630Worms: 06242 4506The chargeable hotline is available on work-days between 5 PM and 7 AM as well as 24 hours at weekends and on public holidays (except 24/25/26/31 December, 1 January and the Easter holidays) on 09001 272874.

SERVICE

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ARBURG GmbH + Co KGPostfach 11 09 · 72286 LossburgTel.: +49 (0) 74 46 33-0Fax: +49 (0) 74 46 33 33 65e-mail: contact@arburg.com

Choose efficient production: Increase product quality and reduce unit cost.

How? By choosing maximum productivity with the fastest cycle times using energy-efficient, high

uptime systems. The 100 % solution can only be found at ARBURG!

Cycle time

Efficiency

Availability