from the editor

Automation: It's the way to go

Times sure have changed over the years for the plastics injection molding business. Once, engineers manually calculated runner systems and gate locations, generated 2D drawings and walked the documents down to shop floors to explain the production process to mold operators. Today, increasing numbers of manufacturers are realizing the benefits of investing in innovative software technologies that automate what used to be time-consuming engineering and machine set-up processes.

This shift owes thanks in large part to software developers pumping out top-rate 3D CAD systems, such as SolidWorks, Pro/ENGINEER and UG, as well as Moldflow creating state-of-the-art software that complements the CAD systems and helps manufacturers design high quality plastic parts and molds before committing to steel. Moldflow also provides technologies to raise efficiencies on the shop floor, so that plastic injection molding machines can be set up, monitored, and documented at the click of a mouse. Engineers and designers in the engineering department can download files to the shop floor, eliminating the need to generate drawings and provide on-floor explanations with shop floor operators. The production information is immediate and understood, thanks to easy-to-use and easy-to-understand programs both in engineering and on the shop floor.

As a result of these automation advancements, cycle times have been drastically reduced. Confidence in designs is elevated, and production schedules are being met and, in many cases, exceeded. Case history after case history documents companies that are reaping the advantages of investing in the automation technology and training that software developers offer to help their customers retain their competitive edge.

For instance, I recently talked with Dr. Anka Bernnat, of BASF's CAE Service in Ludwigshafen, Germany. Her team primarily provides structural mechanical analysis to internal customers - sales and materials buyers. She said they use Moldflow Plastics Insight (MPI) software extensively to advise customers on mold designs and issues such as injection points to select if a mold is not running as expected. They help correct errors and sort out problems that were not expected - troubleshooting. With new contracts, they calculate mold designs to advise customers in advance. She uses MPI software to speed up the process of obtaining results and to improve part designs. She says small modifications can make a big difference in the end result. The biggest benefit of using MPI software is to optimize molds on-screen versus doing it manually on the actual mold.

She said, "In large part, European engineers understand the importance of utilizing CAE and value the results. The issue is companies need experts who can evaluate the results and steer companies away from problem areas before committing to production. One hour spent with the customer going over the results has significant ramifications in the customer being able to interpret our work and generate a quality part. Moldflow helps us communicate with and educate customers and enable them to move forward with problem-free production."

We hope more manufacturers who have yet to move from the manual methodologies to an automated environment will take heed and seriously consider Dr. Bernnat's commentary and the other offerings provided in this issue. This information should provide impetus for those companies to update engineering and production processes with technologies and training that can move them into the 21st century technology with innovative means of meeting customer demands that can cut costs and improve product development.

Laura Carrabine
Editor