A good mold manufacturing enterprise, to create high-quality mold products, and considerable profits, must have its own place, such as Dongjiang mold sales in 2013 close to 600 million yuan, analysis of its causes, it has the following characteristics: perfect system, efficient team, super execution, innovative spirit. Setting aside the strategy and direction of these companies, this paper mainly expounds the system construction and on-site management of mold factory.
I. organizational framework and working rules
For the mold manufacturing department, different companies belong to different, like Dongjiang is the fitter responsible for all mold follow-up, Bellos and Nipple have TE and pipe follow-up mold all the matters. The author uses Dongjiang's mode to manage subdivision. The advantages of this model are quick response and high efficiency.
1. design department --ESI review, mold design.
Mainly responsible for the early ESI review, mold design, information communication with customers, product review, can also provide technical support for the quotation. If the product is single and the cycle is short, the mold can be made into standard parts, such as pressing block, wear-resistant sheet, limit column, prop, inclined guide post, and even front and rear mold and row can be designed into standard parts, greatly speeding up the manufacturing cycle of new mold.
2. processing department -- programming, CNC, EDM, EDW, Gong mill.
Mainly responsible for the allocation of processing and production processes can coordinate and cross each other, so that the processing section can be maintained unobstructed, so that the blocking process can be transferred to the next process in time, can greatly reduce the coordination between groups, shorten the time of communication, so that the mold can be put into production in time to ensure the quality and delivery of the mold.
3. assembly department mold assembly, TE and mold modification, polishing.
Fitter is responsible for mold assembly, modification of mold plan, and maintenance of mold. Master responsibility system is adopted to follow up the details of the responsible mold, including materials, processing, the progress of standard parts, etc. to be responsible for the final delivery time of the mold, mold quality is qualified. TE is mainly responsible for following the mold, leading the formulation of modification mold plan, mold design phase of the structure review and other related mold technical issues.
4. planning and technology section (PMC).
Work out production plan and follow up production schedule. Work out parts hour, statistics mold cost, exception handling, process layout of parts processing, etc.
From the beginning of the processing, the author elaborates on the specific system construction and site management.
1.CAM programming group
CAM programming plays a vital role in mold production. Programmers'unreasonable programming or insufficient technical ability may lead to a workpiece processing time more than twice or more in CNC machine tools. Secondary development of UG, programmers unified use of UG processing template, UG tool library, the unified setting of parameters, no need to adjust too many parameters, can reduce the manual input of processing parameters and errors, improve programming efficiency and CNC machine tool processing efficiency, improve processing accuracy, at least four points can be saved. About one of the manpower, and can improve the efficiency of machine tools.
The technical level of programming is directly related to the quality, precision and efficiency of CNC, EDM, line cutting, Gong grinding, assembly.1) make standard UG mold processing templates and plug-ins, all programmers use it. In order to improve programming efficiency and reduce errors, it includes speed and speed of cutting tools. Determine the reasonable processing parameters such as mold kernel, insert, mold embryo and electrode, strictly implement the program to control the NC speed, prevent CNC program changes in the workshop, improve efficiency.
2) The program is written according to a single, single knife number, which is easy to operate in the CNC workshop when repairing, and does not require programming alone to write the program.
3) develop a complete manual for programming manuals, including steel, graphite, copper and concrete processing instructions.
4) develop the LINK files for the two time, reduce manual operation and improve efficiency.
5). Two development program, mature paperless operation, CNC workshop open PDF files can be installed.
6) Electrode automatic discharge, cooperate with EDM, redevelop automatic discharge. The basic concept is that the operator installs the electrode, after dividing the workpiece, open the CNC file automatically generated by programming, automatic discharge, including automatic completion of XYZ data, automatic setting of discharge parameters, current pulse width and so on.
7) Workpiece automatic detection, secondary development in cooperation with QC, automatic detection, the basic concept is that the operator installed electrodes on the three elements, after the center, open the CNC file automatically generated by programming, automatic measurement of relevant detection points.
8) Collect and summarize common programming errors, formulate "CNC mold programming common anomalies" for programmers to learn, to eliminate programming anomalies.
9) Programmers work in accordance with the "CNC Programmer Work Standards", "CNC Mold Programming Parameters Standards", "CNC Mold Programming Common Exceptions" programmer responsibility to follow up their own programming mold NC progress.
10) Programming in the completion of a set of mold, listing the program and electrode list, distributed to. NC, EDM, wire cutting, mold room, the relevant personnel can very clearly and timely understand the progress of their required program or electrode. NC, EDM, wire cutting, mold room, according to the overall mold schedule, timely scheduling work.
11) Programming early in the design to participate in design review, check the design, after the completion of the design, processing review meeting, the programmer promptly remove the electrode out of the order sheet, then write the electrode program out of the discharge drawings, and then write the steel program. And fill in schedule information on schedule.
2.CNC machining group
CNC group is an important part of mold manufacturing, and its processing quality and efficiency are directly related to the success or failure of mold. This group needs to be composed of hardware resources, operator, production technology process, departmental specifications and other parts of the software and hardware effective combination, so that production quality and efficiency to meet production requirements.
The tool holder is used to clamp the tool for workpiece processing, the closed tool holder is used for machine tool selection, the open tool holder is used for machine tool, the tool holder is easy to scrap and other debris on the rail, and the tool holder is easy to be jammed when changing the tool, and the machining accuracy will be greatly reduced, such as too much deviation in tool clamping, it is possible to use the open tool holder. Artifacts will be scrapped.
The transmission mode is LAN connection, one computer controls many CNC machine tools, which is easy to manage and saves the cost of computer hardware.
CNC machining electrodes need to use EROW or 3R system of rapid clamping, synchronous with the spark machine, all electrodes do not need minutes to take the number, directly call the programming program can be processed, all parts processing, the operator needs to do is to clamp the workpiece and call the programming program, the processing speed of all programs by the programming program Control, in order to standardize and unify the processing speed, prevent the operator of the machine tool processing speed control arbitrariness, require the operator to machine tool feed knob switch can be hit, and then by the machine tool automatic tool change, automatic processing, processing only to check whether the workpiece is qualified, and then clean up, off the machine can be.
Medium-term planning uses the pre-adjusting table outside the machine, before processing, calibration sub-workpiece, directly on the machine processing, saving clamping time. Long term planning uses automatic production line system.
1) hardware machine tools, software programs, procedures, automation.
2) The operator can install the knife according to the program without modifying the speed and feed of the program. Prevent manual errors.
3) cooperate with programming to realize paperless operation. Cost saving and efficiency improvement.
4) Strict implementation of the three inspections (first inspection, mutual inspection, self-inspection), three no (do not find out the reasons do not pass, do not implement preventive measures do not pass, non-conforming products do not flow out).
5) Tool precision wear inspection after machining to ensure that the quality accuracy of the processed workpiece reaches the FIT mold once completed. No use of a knife.
6) tools in the knife store regularly check every day and replace the unqualified tools in time.
3.EDM electrical discharge machining unit
Discharge machining (EDM) plays an important role in the mold industry. It has a wide range of machining, small cutting force, easy to form. It can process almost all shapes, such as small holes, carbide machining, mirror machining and so on, and can do special surface machining with a wide range of machining.
The cost of graphite is about 1.5-2 times that of copper, but the discharge speed of graphite is 30% faster than that of copper, and the forming speed is more than 50% faster than that of copper. Graphite discharge is of great significance to the fast delivery of mobile phone moulds. .
The spark machine adopts EROWA or 3R fast clamping and positioning, and develops automatic discharge system. All electrodes, including oblique glue electrode discharge machining, do not need minute calibration, and do not touch the number of electrodes. The discharge data of electrodes are generated in batches in one time by UG software in the computer, without input any discharge parameters, as long as in the machine tool. The number of input electrodes can be automatically discharged. In this way, each machine can save about 2 hours a day of clamping time, from the original per capita operation of two machines can be reduced to per capita operation of three machine tools processing, but also can avoid manual input discharge parameters caused by errors in the workpiece error. If the company is well-funded and can use the pre-adjusting table outside the machine, before processing, calibrate the sub-workpiece, directly on the machine processing, saving clamping time.
1) cooperate with programming to realize paperless operation, save cost and improve efficiency.
2) Secondary development, to realize EDM discharge automation, programming, standardization, the basic concept is that the operator installed the electrode, after the workpiece is divided, open the CNC file automatically generated by programming, automatic discharge, including XYZ data automatic completion, discharge parameters automatically set, current pulse width and so on.
3) Manipulator fool-type anti-daze operation, according to the program can be processed, do not need to modify the program to prevent manual error.
4) strict implementation of three inspections, three no.
4.EDW wire cutting group
In the mold industry, EDW is an indispensable component, from the original fast wire to the present precision slow wire.
Line cutting needs to be equipped with a variety of parts fast clamping fixtures, which can effectively improve the clamping time, reduce parts minutes and comparison time, save labor costs, processing non-precision parts can be used in the middle of the wire machine tool roughening (such as inserts, rows, inclined roof, etc.), in the middle of the wire roughing time is twice as fast wire, processing precision zero. Parts, can be processed with galvanized wire, galvanized wire processing speed is 13% of the copper wire, but the cost of galvanized wire than copper wire will be slightly higher.
1) cooperate with programming to realize paperless operation, save cost and improve efficiency.
2) two development, to achieve EDW processing standardization and standardization.
3) The line cutting program is programmed by a special person, and the operator works foolishly in accordance with the program, without modifying the program to prevent manual errors.
4) strict implementation of three inspections, three no.
5. gongs mill
Car, milling, grinding and drilling are related parts of mold production department.
The lathe is mainly used for machining shape, inner hole, thread and circular material. Milling machine is mainly used for processing ejector pinholes, screw holes, water holes, spring holes, tapping and rough machining of die components. The grinder is mainly used for the precision machining of the shape of the mold components, and can process all kinds of high hardness and superhard materials. Drilling machines are mainly used for drilling water holes.
The Gong and grinding group belongs to the pure handicraft craft, one person one machine, night shift because of the low production efficiency, low cost of machine tools, depreciation rate is also low, so it is not suitable for overnight production, usually to produce molds, not busy, can process mold standard parts inventory, to be used in future mold assembly, inventory mold standard parts if can be used in large quantities. It can greatly reduce the processing time of parts and shorten the production and processing cycle.
1) Training staff Gong grinding process, master the common causes of grinding and milling defects and prevention methods and other professional knowledge.
2) to train common tools, tools, measuring tools for construction, use, adjustment and maintenance.
3) train common tools, types, grades, specifications, properties, uses and maintenance methods.
4) training metal materials, grades, milling performance, thermal expansion and cold shrinkage properties.
5) to train employees to understand the method of drawing and understanding, and the conversion and application of trigonometric functions.
6) training machine specifications, performance, structure, transmission system and adjustment methods.
6. mold assembly group
Assembly is a process after all the processing is completed, and it is in a key position in the whole mold manufacturing. From the perspective of precision mold production, the requirements for the management and operators of the assembly workshop are also very strict. It reflects the requirements for product quality, mold parts finishing data, appearance maintenance, but also requires me to have a good sense of quality and operating skills with the operator.
Assembly operation is manual operation, requiring clear thinking and meticulous manual work. Before getting the workpiece to assemble, we should check the glue position, clearance angle position and assembly position. Attention should be paid to the operation method in the assembly. Grinding machine is forbidden in FIT. Sandpaper and oilstone are allowed to remove the knife grain in a few places.
1) Formulate the standard "Guidelines for Mould Assembly Operation" to guide the FIT die entry operation methods such as row position, inserts, inclined roof, mold kernel.
2) Formulate and improve the "Mould Assembly Technical Manual", collect and know the assembly cases, do regular training of teaching materials.
3) carry out abnormal or experience summary regularly every month, and each master instructors do PPT training materials.
7. mold TE group
TE modification mold plan is very critical, some mold factory TE professional ability is not strong, resulting in frequent repair mold, except for customer modification, itself repair mold more than ten times are common. The cost of repairing a mold is thousands of yuan less, and tens of millions more. One of the main reasons is that a mold factory is not profitable.
1) For the common mold problems such as cape, shrinkage, deformation, weld wiring, top whitening and so on, the detailed solutions are listed in different categories.
2) For dimension modification, it is necessary to start with the 3D inspection of steel, then to the product, and then to the injection parameters, and gradually check the reasons.
3) TE should sum up the experience, every time the repair failure to review the reasons, to eliminate the repair program into an experimental program.
8. process planning section
The plan is related to the progress control and delivery of the entire mold, the process directly affects the accuracy and efficiency of the mold, as well as the quality of the final mold products. Each part has a different way of processing, it needs to be combined with the cost of processing, easy to operate, time efficiency to consider, reasonable arrangement of process flow.
1) The plan sets out a detailed schedule, including the detailed process of design, ordering, feeding, mould embryo, drawing, standard parts, bulk parts, mould core, insert, inclined top, row position, pressing block, wear-resistant sheet, etc.
2) process follow up in time and check the parts status every day according to the schedule.
3) Processing technology to do color drawings (do secondary development), detailed formulation of the processing program, for the front mold, rear mold, row, insert and so on detailed list of processing rules, distinguish programming, CNC, Gong machine, grinder, wire cutting, spark machine, lathe, drilling machine processing sequence and steps, reduce waiting time.
Two, specific management methods
1. machine tool equipment
1) Deeply understand the performance and operation methods of each machine tool, for each machine to develop the "machine tool operation and use instructions" to enable technicians to use the machine tool reasonably and effectively.
2) Collect and formulate the Common Alarm and Processing Methods and train all operators. The technician has the ability to deal with common abnormal policing.
3) According to the relevant recommendations of the machine tool manufacturers and the actual situation, formulate "machine tool maintenance procedures" for the use and daily maintenance of machine tool consumables to ensure that the machine tool has a stable processing accuracy.
2. tooling tool
1) Tool management: to make "Tool Use and Maintenance Instruction" for calibration tables, rods, calipers, knives, electronic detectors, sinusoidal tables and other measuring tools, to ensure that all technicians can correctly use and carefully maintain, and to punish the abnormal damage according to the regulations.
2) Fixture Management: regular grinder for round iron, code board, code bar and other fixtures to ensure accuracy. (and do the size change record), vise, sucker, EROWA, line cutting and other fixtures to do "fixture use and maintenance instructions", so that each technician can be skilled in clamping.
3) tool management: to ensure machining accuracy and control machining cost. The knife head, barrel clamp, knife holder, knife tool, knife grain centralized and unified management, coarse, medium and fine as well as workshop, inventory separate storage. Regular tool inventory, liquidation and purchase application. Make an evaluation record of the use of new tools to understand the characteristics of different types of tool processing different materials, rational use of tools, in order to ensure the quality and efficiency of the premise of reducing tool costs.
3. computer system
1) Build a local area network in the company's local area network, and set different access rights to supervisors, clerks, programmers, transfer computers.
2) Set up computers for different positions according to the nature of the job, install only job-related software, and avoid using company resources to do things unrelated to the job.
3) uniform naming management of documents, and document management standard.
4. workshop environment 5S management
Only good working environment can make good things, make hygienic duty table and regional division, and do a good job of 5S scene environment, can we maintain a pleasant working environment, can we produce good things. 1S. finishing, 2S. rectification, 3S. cleaning 4S. clean 5S. literacy.
5. production site
1) Make a division of the area and mark it out. The machine tool equipment area, the clamping area, the processing area, the completed area, the tool cabinet, the passage and other areas are marked with words, and the responsibility of tidy and tidy work will be assigned to the person to formulate the "Workshop 5S Management Specification".
2) Promote transparent management and publish daily production plan, production arrangement, production summary, quality and efficiency in workshop bulletin boards to create a good working atmosphere.
6. personnel management
No matter how good the hardware resources are, they also need to be operated and completed by people. The quality of people is directly related to the efficiency of equipment and the quality of products. Quality and efficiency are mainly determined by hardware equipment, process, technician's quality, production management and so on. And the quality of the technician is the most important, its quality directly affects the quality of the workpiece, the efficiency of the high or low. The quality of the operator can be improved from the following five aspects:
1) Work mentality: a good mentality is the fundamental to do a good job, usually more effective communication with them, work is superior and subordinate, work is a friend, so that they feel the warmth of the team. Cultivate their active, careful and responsible work habits.
2) Basic Common Sense: As an experienced technician, the understanding of basic common conditions is very important, the direction of the workpiece placement, proofreading, dividing, these common sense operations every technician should be skilled in operation, to resolutely eliminate mistakes. The warning slogans will be posted, the development of standard methods of conventional operations, usually repeated emphasis on these common sense operations, never allow such low-level errors.
3) Skills training: Develop various machine operation instructions, on-site training for new employees and the old staff responsible for "pass, help, take" method, so that they can be familiar with the operation of the machine as soon as possible, in order to facilitate continuous production.
4) Quality and efficiency consciousness: cultivate the staff's quality and efficiency consciousness, and formulate the quality processing model of mold kernel, insert, mold embryo and electrode. Let every employee know what kind of workpiece we want to produce to be qualified, and stop the flow of NG products to the next process. In addition to investigating the relevant responsibility for abnormal work pieces, we should also analyze the causes, specify preventive measures, and post them for publication to prevent the same mistakes from happening again. Develop fast clamping specification, reduce idle time and improve production efficiency.
5) Promotion management generally programmed personnel flow is smaller than NC, EDM, EDW technicians, when the programming needs to be good in the company's service 1-3 years of technicians withered to programming, can leave some people wanted, and can bring the enthusiasm of the staff.
6) employees must obey the work arrangements of their superiors without delay or confrontation.
7. system standard
With the hardware system and personnel, we need reasonable rules and regulations to guide everyone, so that we have a fair, positive, vibrant working atmosphere. We can explain the system specifications we need to use in the process of die processing.
1) communication must be provided with the "transfer list" for the specification of drawings and files.
2) Employees are required to fill in the "Work Daily Report" daily. This form collects the rate of machine tool spoilage, evaluates the performance of employees, and counts the cost of molds.
3) Performance norms, in order to improve the enthusiasm of everyone, according to the "work daily report" of the work content, performance appraisal.
8. technology reserves
As a technical industry, we should not only train a few technicians on designers, programmers and technicians, but also form a set of valuable technical information and operation process, so that we can produce safely and efficiently no matter what position is suddenly vacant. The main information includes:
1) machine tool operation data.
2) information on mechanic operation.
3) programming technical information.
9. production arrangements
The company produces profits through the production of products, the above said is to lay the foundation for efficient production, pave the way, do a good job in production, do high-quality products, get customer recognition is our ultimate goal. For this reason, the control of the workshop on production is very important.
1) The plan of the whole set of molds is to hold a processing review meeting in time after the customer has formally ordered the molds. The supervisors are called in to work out the schedule, including the specific time of mold embryo, material fixing, design, programming, computer addition, CNC, EDM, line cutting, assembly and so on.
2) According to the overall mold planning schedule, hold a party to know the mold status of the Department in time, adjust the work schedule, and cooperate with the overall mold planning.
3) Implement computer networking management, each workpiece on the machine into the computer system, patrol the workshop from time to time, to solve processing problems. The machine parts are strictly self checked, and the data are recorded, and the self-test reports are kept. A continuous shift system is adopted to arrange operators to take turns to eat and ensure timely delivery.
4) carefully track the processing status of each mold, ensure the accuracy of the data and record it into the computer system. So that any manager with permission can clearly understand the completion of each mold through the computer system.
5) Weekly summary of the department's output value, abnormal countermeasures, and new technology learning. Make every employee aware of the department's shortcomings and make the production situation transparent.
Three. Salary and benefits
At present, some companies adopt the base salary plus bonus to calculate salary. The advantage of this method is that it can improve the enthusiasm of employees and increase the production output effectively. But its disadvantage is that it can not ensure the quality of molds. The staff work as long as they complete the task that is up to the standard, the sense of responsibility is not strong, so it is not advisable to produce higher precision molds.
Some companies use the base salary + allowance + overtime pay to calculate wages, but the overtime rate needs to be reasonable, not too high, not too low, too high overtime will lead to low productivity, employees in the work time not completed work will be left to overtime at night to do, which will produce a lot of overtime, leading to enterprises Industry increases a lot of labor costs, but too low overtime pay can also lead to employees do not want to work overtime, such as mandatory overtime, staff responsibility will gradually decline, productivity and quality will become slowly low, so the ratio of overtime pay needs to find a relative balance.
Four. Summary
No matter how good the system and process are not supervised and executed, it is also waste paper. Team building is very important. Talents are very rare. If an enterprise wants to make a profit and develop, besides the adequacy of the order quantity, the quality and delivery date of the products are particularly important. These require a number of technicians and people with strong responsibility and ability to complete the work. Appropriate promotion and salary increase, the ability of poor staff to be eliminated resolutely, the company management must be clearly rewarded and punished, so that the enterprise can develop considerably.
