A tool logbook on paper is often not to hand just when you need it most. Or it is incomplete, since it is time consuming to keep the information up to date. A cloud-independent, electronic tool log, which is directly integrated into the tool could make all the relevant data available directly.

The Electronic Tool Logbook as a Combination of Operating Manual and Check List

Werkzeuginnendrucksensoren

Messtechnik

Sensoren / Messwertaufnehmer

Messdatenerfassung und -verarbeitung

Software

Papierlose QM-Dokumentation

Qualitätsmanagement

Dokumentationsmanagement

Werkzeugkonstruktion

Dienstleistungen

Werkzeug-, Formen- und Modellbau

Werkzeugüberwachung

Toolmanagement

Mobile Datenerfassung

Logistik

Lagertechnik

Digitale Transformation

Wirtschaft

Innovationen und neue Technologie

Spritzgießwerkzeuge

Kunststoffverarbeitung: Maschinen und Komponenten

Werkzeuge für die Kunststoffverarbeitung

Werkzeug- und Formenbau

Fernwartung / Ferndiagnose

Instandhaltung

Dokumentenmanagement, CAQ

Qualitätssicherung

Data Management at the Tool

Susanne Schröder will become editor-in-chief of the magazines Kunststoffe and Kunststoffe international on December 1, 2020. The current editor-in-chief Dr. Karlhorst Klotz will leave the company by mutual agreement.

Werkzeuge für Leichtbauwerkstoffe

Präzisionswerkzeuge

Tiefziehwerkzeug

Werkzeugwechselsysteme, Spritzgieß

Modulare Werkzeugsysteme

Absaugungen für Werkzeugmaschinen

Betriebsausrüstung / Betriebsmittel

Absaugvorrichtungen

Fluorkunststoffe

Kunststoff Werkstoffe

Thermoplaste

Werkzeugverwaltungssoftware

Prüfen von Kunststoffen

Biokunststoffe

Presswerkzeuge, Kunststoff

Werkzeugreinigung, Kunststoffe

Standardkunststoffe

Kunststoffverarbeitung

Lohnfertigung

Technische Kunststoffe

Füllstoffe für Kunststoffe

Kunststoff

Bauwesen

Baustoffe

Kunststoffhandel

Handel

Betriebstechnik für Kunststoffverarbeitung (Peripherie)

Kunststoffverarbeitung: Verfahren

Kunststofffasern

Verstärkungsstoffe

Kunststoff-Recycling

Kunststoff-Aufbereitung

Hochleistungskunststoffe

Qualitätssicherung Kunststoff

Change in the Chief Editorial Office of Kunststoffe

The consumables required for In-vitro diagnostics are manufactured in a production process that is subject to high requirements in terms of precision and quality, but also the complex cleanroom manufacturing environment. This has implications for the entire plant technology – especially toolmaking.

Strategic Approach through Classification according to Product Groups

Spritzgießen

Medizinprodukte

Medizintechnik

Mold Platforms for IVD Consumables

Munich-based mechanical engineering group KraussMaffei is repositioning itself and uniting all divisions under a single brand. At a time of accelerated technological change, the company is increasing its efforts to develop new products for digital solutions and new business models – and that includes plastics recycling.

KraussMaffei Consolidates Three Divisions and the Previous Group Brands under a Single Brand

Extrusion

Doriat, Clemens, Dr.

Spritzgießmaschinen, allgemein

Spritzgießmaschinen

Nachhaltigkeit

Umweltmanagement

Industrie 4.0 für die Kunststoffverarbeitung

Industrie 4.0

Ressourcenmanagement

Produktion

Compoundieren

Moving with the Times

Since 2007, one major construction project has followed another at Arburg in Lossburg, Germany: customer center, assembly hall, tradeshow logistics hall, training center and currently the next assembly hall. While environmentally friendly construction and production methods have long been established at the site, the company is now announcing an eco-efficiency program for the injection molding world, bearing the name “Arburg Green World.”

Arburg Is Pursuing a Closed Value Chain for Plastics

Energieeffizienz

Green Wave

Once again, the K 2019 in Düsseldorf, Germany, lived up to its claim to be the leading trade show for plastics technology. At least in the field of injection molding, there were exciting global innovations to see – if you looked closely.

Injection Molding Trends at K 2019

Schaumspritzgießen

Smart Factory

Mikrospritzgießen

Mehrkomponenten-Spritzgießen

Fließpressen

Handling, Handhabungstechnik für die spanende Fertigung

Automatisierungstechnik

Handling, Handhabungstechnik

Spritzgieß-Sonderverfahren

Spritzgießsimulation

Simulation

Elastomer-Spritzgießen

Linearroboter für die Kunststoffverarbeitung

Industrieroboter

Montagetechnik

Montage-Spritzgießen

Knickarmroboter

Co-Injektion (Barriere-/Sandwich-Spritzgießen)

Hybrid-Spritzgießen (Metall / Kunststoff)

Technical Excellence thanks  to Digital Assistance

During this year’s pandemic, maintaining supply capability has become a key necessity among processors. Closer involvement of suppliers is only logical in these circumstances. In toolmaking, new challenges are emerging for services related to molds.

The Advantages of a Network for Global Qualification for Injection Molding

Erstbemusterung, Erstmusterprüfbericht

Werkzeugbau

Inline- / Online-Messsysteme

Fast and Effective Start of Production

Unforeseen downtimes in serial production are always accompanied by high costs, making it essential for machines to be serviced in time. Because sensor, transmission and data storage technology have taken a big leap forward in recent years, predictive maintenance has already been realized in some industries, demonstrating a tangible benefit of Industry 4.0. The WZL and the WBA have developed a guideline for this.

Guideline to the Development of Predictive Maintenance Systems for Serial Producers and Toolmaking Companies

Industrie 4.0 für die Qualitätssicherung

Condition Monitoring / Prozessüberwachung

Sensoren verschiedener Messverfahren

Fertigungsautomation

Sensorik / Aktorik

Machine Learning

Datenanalyse

Dienstleistungsqualität

Instandhaltungsmanagement (TPM)

Vorbeugende Instandhaltung für die Qualitätssicherung

Machine Learning für die Qualitätssicherung

Symbiosis of Toolmaking and  Serial Production

At HRSflow‘s headquarters in San Polo di Piave, Italy, a new production facility for hot runner systems based on lean manufacturing principles was recently completed.

3000 sqm for Lean Manufacturing

Normalien und Heißkanaltechnik

Komponenten für die Kunststoffverarbeitung

HRSflow Expands Headquarter

The signs point to growth: more exhibitors, more internationality and (as far as predictable) more visitors – this is only the second edition, but nevertheless, the Moulding Expo trade show is on its way to establish itself as the leading fair of tool, model and mold making in Europe. Booth bookings from the core area of the industry are over average, which is proof of the acceptance of Messe Stuttgart, Germany. 

Moulding Expo Will Take Place at the End of May, with More than 700 Exhibitors 

Verbände, Institutionen, Messen

Messeveranstalter

"We Want to Be more International" 

Right from start, the goal was to create a trade show "by the industry, for the industry." Mission accomplished: about half of the roughly 700 exhibitors at the second Moulding Expo were from the tool, model and mold making industry. Here is a small selection from the range of topics. 

Mold and Tool Makers Now Have a New Home: Moulding Expo 

Oberflächentechnik

Unmissable 

Some 38 years after it was founded, the tool manufacturer Haidlmair celebrated its first technology open day with an extra special obstacle course. The highlights were the demonstration of a new CNC automation system and an enhancement of an open hot runner nozzle system promising higher productivity chiefly for the production of logistics containers and technical parts. 

Haidlmair Combines the Advantages of Injection Molding and Extrusion in One Tool 

Gate Quality under Control 

The producing industry is increasingly involved in changes due to progressing globalization and derivatization, shorter product lifetimes, and demographic change ¿ with enormous consequences for mold making as well. This is why mold making companies have to continue further development. In actual practice, a so-called 3C approach to "compare, compile, and conduct" has proven effective. 

Compare, Compile, Conduct ¿ Further Strategic Development in the Tool and Die Industry 

Maßnahmenmanagement

Benchmarking

Strategie und Organisation

In between Industry 4.0  and Market Intelligence 

At a time of increasing complexity in production, efficient and rapid production and decision-making processes are essential in order to remain competitive. A fundamental requirement for this is complete transparency throughout the entire process chain ¿ including in tool and mold making. One option for creating the necessary infrastructure and transparency for rapid and improved decision-making is to use apps. 

Towards Agility and the Internet of Production with Mobile Applications 

CAD Werkzeug-, Formenbau

ERP-Systeme

Workflow- / Prozessmanagement

Apps in Individual and  Small-Series Production 

Marbling is often a real eye-catcher in plastic components. However, the effect is difficult to create and there are some pitfalls when it comes to reproducibility. Novel nozzles for injection molding machines in combination with a special dosing technology allow marbled molded parts to be produced far more easily in a much more robust process.

A 3D-Printed Nozzle and Modified Dosing Method Deliver Reproducible Marbling  in a Robust Process

Kunststoffe

Photonik

Optik

Additive Fertigung

Farben, flüssig

Additive

Exciting Design instead of  Exciting Manufacturing

Toolmaking of the Future –  Digitalized and Sustainable

What the Two Trend Topics Mean for Collaboration between Toolmaking and Series Production

The toolmaking industry of the future is facing significant changes in its range of services and its value creation processes. It is difficult to predict exactly how the collaboration of German tool manufacturers with series production will be structured in the future. However, it can be assumed that digital networking and sustainability will play a key role.

The toolmaking industry in Germany is facing a variety of different challenges in 2021. Even before the Corona crisis, the market for new tool purchasing tended to act in a wait-and-see manner – at the same time, more and more high-quality international toolmaking companies are entering the market, many of those have now established their own service locations in Germany. The Corona crisis has led to a further delay in the recovery of the global tool demand. Therefore, the long-term development of the toolmaking industry beyond this time is difficult to forecast and depends on a large number of different influencing factors. However, it can already be identified that all development scenarios have two content-related commonalities.

First of all, digitalization: in the long term, toolmaking companies can only secure their competitiveness if they significantly increase their efficiency and realize new differentiation factors. Both are only possible with digitalization, as the potential of classic lean methods has largely been exhausted and international competitors are increasingly adapting existing differentiation factors.

Besides, sustainability: up to now, political and social sustainability activities have only had a very limited influence on the toolmaking industry. However, since series producers and capital providers are focusing increasingly on sustainability, there is an acute need for action for the toolmaking industry to ensure access to new orders and capital in the long term.

The two aspects digitalization and sustainability will be explained in detail regarding their significance and implementation in toolmaking.

Digitally Connected Internally and Externally according to Requirements

The digitalized tool shop is connected internally and externally according to requirements to make its own value creation process more efficient and to increase the benefits for series producers. The WBA Tooling Academy target image of a digitalized tool shop describes how the design of concrete applications for realizing the benefits of digitalization in toolmaking has to take place (Fig. 1).

 In addition to the tool shop itself and the series producer, external value creation processes of suppliers also have to be taken into account.

Possible use cases of digitalization are classified in the four maturity levels of

<ul><li>visualization,</li><li>transparency,</li><li>forecasting and</li><li>adaptability.</li></ul>

Solutions for the visualization of data (e. g. display of machine data) represent the entry into digitalization, as they already require an available and cleansed database, which is mandatory for all further levels. Based on this, transparency about the causes of conditions can be created by identifying correlations in the database (e. g. factors influencing the life cycle of milling tools). Knowledge of this enables a forecast of these states, which forms the basis for an automated reaction to a forecast system state (e. g. avoidance of tool breakdown).

Based on the benefits, the IT perspective of use cases have to be designed. This is often not visible to the actual user, but it requires the greatest effort during the development phase. The IT perspective is designed on the levels of data sources, middleware and data analysis. For this purpose, data from different systems often have to be examined and newly collected in toolmaking (e. g. planning and machine data). To aggregate data, middleware is required to provide the data from different systems for analysis and utilization. In addition, toolmaking companies must address the organizational (e. g. qualification of employees) and technological (e. g. framework conditions for using tablets on the shop floor) enablers of the solution. This provides the basis for successful implementation or use of a solution.

The digitalization not only supports toolmaking companies in increasing their own efficiency and the benefits for the series producer, but it is also a central enabler for true sustainability. By creating transparency along the entire life cycle of a tool (tool development, tool production and tool use) and across all stages of the value chain, sustainability can be evaluated and optimized in a valid manner.

Toolmaking as an Enabler of Sustainable Series Production

The implementation of sustainability demanded by series producers and capital providers poses a great challenge for the toolmaking industry. In the WBA study “Competitive Factor Sustainability – A Differentiator for the Tool and Die Industry”, it is described how toolmaking can increase its own sustainability in the future as well as the sustainability of the series producer. For this purpose, a target image was developed that shows the fields of action of sustainable toolmaking and that is intended to serve as an introduction for toolmaking companies to the topic of sustainability (Fig. 2).

In line with the target image, the fields of action service range, resources, process and employees are no longer to be optimized from a financial perspective alone, but against the background of the “Business Case for Sustainability”. This means interpreting the eco- and socio-effectiveness demanded by stakeholders against the background of entrepreneurial thinking as eco- and socio-efficiency. In total, the terms eco-efficiency and socio-efficiency summarize the symbiosis of ecological, social and economic aspects in order to make sustainable actions of toolmaking companies economically attractive. With the sustainable design of the service range, toolmaking companies primarily pursue the goal of supporting the series producer in its sustainability.

In addition to measures implemented directly related to the tool, such as the insulation of an injection molding tool to reduce the tempering effort, these measures also include more far-reaching activities in the process. These can include, for example, the material selection of the article or completely new services, such as the reuse of tool components.

With the other three fields of action, resources, process and employees, the toolmaking company ensures that it will be able to provide its services more sustainably in the future, when compared to the competitors. This is of particular importance, as in the future, to ensure their own sustainability, series producers will evaluate sustainability performance in addition to tool price when procuring tools. Initially, this will manifest itself in general certifications and audits. Customers will demand proof from toolmaking companies so that they are generally considered as a supplier. In the medium term, however, this will express itself in a tool-specific assessment of CO2 emissions and then holistic sustainability, which will be assessed quantitatively.

The future development of collaboration between German toolmaking companies and series producers will be determined by a variety of influencing factors. All development scenarios have in common that they will be characterized by digitalization and sustainability. To be able to successfully exist on the market in the long term, toolmaking companies must therefore take the following steps to get started in the two topics.

Firstly, a strategic definition of use cases for internal optimization and increase of customer value based on digitalization is necessary. Besides, the implementation of prototypical applications based on already existing data, to generate a basic understanding is useful. As a further aspect balancing of own CO2 emissions on company and tool level as an introduction to the topic of sustainability is helpful. Lastly, deriving measures to increase the company’s own sustainability and that of its customers, based on the main factors identified as influencing the sustainability balance sheet is necessary.

Werkzeugmaschinenlabor WZL der RWTH Aachen University 

https://www.wzl.rwth-aachen.de

WBA Aachener Werkzeugbau Akademie GmbH  

https://www.werkzeugbau-akademie.de

Ausgabenartikel

Fig. 1. Target image of the digitalized tool shop to increase its own efficiency and support the series producer