注塑指导Competitive Injection Molding by Kazmercost

(42页)

'注塑指导Competitive Injection Molding by Kazmercost'
COMPETITIVEINJECTION MOLDING David O. Kazmer, P.E., Ph.D.SME/Eastec 2004 Conference Springfield, MA 1 Agenda? Economic Structures & Data? Evaluation of Injection Molding ? Barriers to Competition? Modern Molding Technologies? Summary 2 Cost Structures Total Production Costs Total Total Total Labor Consumables Facilities Costs Cost Costs$/Hr Machinery Facilities Output Energy Maint’nceDowntime Yield Resin 3 Cost Parameters? Cost parameters N.E. China – Operator labor $13/hr $0.70/hr – Eng/Mgt labor $30/hr $3/hr – Energy cost $0.08/kWh – ABS resin $1477/ton $950/ton – Machinery cost $30/hr $15/hr – Facilities cost $7.00/ft2 $4.20/ft2 – Maintenance rate 10% 20% 4 Agenda? Economic Structures & Data? Evaluation of Injection Molding – Class 0: Obsolete – Class 1: Standard – Class 2: Efficient – Class 3: Lights Out? Barriers to Competition? Modern Molding Technologies? Summary 5 Injection Molding Economics? Case Study for a Mid-Sized Molder – 200 million parts per year – Average part weight: 10g 6 Class 0: Obsolete Operating Conditions? 8 cavities/mold with cold runners? Poorly selected hydraulic machines (26 kW)? 50 seconds per cycle (optimistic) – Cooling issues & semi-automatic? 95% quality level (optimistic)? 1 operator per 1 machine? 1 eng/mgt per 15 operators? 2 shifts, 5 days per week? 4 hour setup per 10,000 parts 7 Class 0: Obsolete Factory Characteristics#Machines #Operators #Eng/Mgt Energy Use 8Class 0: Obsolete Cost Data 9 Class 1: Standard Operating Conditions? 16 cavities/mold with 50% hot runners? Well selected hydraulic machines (30 kW)? 45 seconds per cycle (optimistic)? 98% quality level (optimistic)? 1 operator per 2 machines? 1 eng/mgt per 15 operators? 2 shifts, 5 days per week? 2 hour setup per 10,000 parts 10 Class 1: Standard Factory Characteristics#Machines #Operators #Eng/Mgt Energy Use 11Class 1: Standard Cost Data 12 Class 2: Efficient Operating Conditions? 32 cavities/mold with hot runners? Electric machines (26 kW)? 40 seconds per cycle, fully automatic? 99% quality level? 1 operator per 4 machine? 1 eng/mgt per 15 operators? 3 shifts, 5 days per week? 1 hour setup per 10,000 parts 13 Class 2: Efficient Factory Characteristics#Machines #Operators #Eng/Mgt Energy Use 14Class 2: Efficient Cost Data 15 Class 3: Lights Out Operating Conditions? 32 cavities/mold with hot runners? Electric machines (22 kW)? 35 seconds per cycle – Fully automatic including crating, etc.? 99.9% quality level? 1 operator per all machines? 1 eng/mgt per all machines? 3 shifts, 7 days per week? 0.5 hour setup per 10,000 parts 16 Class 3: Lights Out Factory Characteristics#Machines #Operators #Eng/Mgt Energy Use 17Class 3: Lights Out Cost Data 18 Comparison? New England ? China 18 Shipping 16 Production 14 12 10 8 6 T 4 o t a l P 2 r
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注塑指导CompetitiveInjectionMoldingbyKazmercost
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