MoldMaking Technology

OCT 2018

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moldmakingtechnology.com 11 YBMV hard-machining center for a total of three Yasdas, and we have worked on our infrastructure. We put in an all new compressed-air system, an all new chilled-water plant and an all new virtualized-computer server and backbone system, including new wiring, cabling, switches and so on. Every bit of our computer network is brand new. We have an enterprise resource planning (ERP) system that we are in the process of implementing, and we plan to ‚inish that and have the system be live as of January „…. It is an IQMS ERP system and eventually, all eight of the companies currently under the Westfall umbrella will be interconnected in a network as one large company. The primary objective is on the ‚inancial side as it drastically simpli‚ies the account- ing process and the ‚inancial reporting process, but there are several other bene‚its that come with being on the software as well. We have every intention of employing many aspects of Industry ‹. across Fairway and Westfall as a whole. AMA Plastics, one of our sister companies, would be regarded as the flagship company for IQMS implementation because every molding machine in its plant is integrated and moni- tored in real-time using the software. We are still evaluating how well it will work for mold shops and have been test- ing machine monitoring for the last two to three years. We expect that Fairway will roll out a comprehensive monitoring system within the next …„ to …' months. What does Fairway offer customers that sets it apart as a moldmaker? Cockrell: One of the things that we do well for our custom- ers is that we provide very accurate molds. One of the primary reasons for that is that we work in a temperature-controlled environment that only varies about ± one degree over „‹ hours, and that is the entire production shop. We try to evaluate and purchase machines that do not vary by more than .„ inch over „‹ hours because those are machines that we can auto- mate. Machine builders claim that their machines hold .… inch or .„ inch, but the real test of any machine tool is how it performs over time. We put new machines through strenuous evaluation and they must be able to run unmanned and hold tolerance, otherwise we cannot use them. Our alter- native is to regress and put an operator in front of the machine, which is going to cost more. We do a lot of hard machining. We hard-machine shut offs, and we hard-machine molding areas. There is no hand-working of any of our parts when we use this process. There is no such thing as ‚itting. Everything is simply done, and the coordinate measuring machine (CMM) plays a critical role in how we get to that point. There is a demand for highly accurate mold components, so we invested in Zeiss CMMs to integrate into the manufacturing process. Our customers tell us that when they run our molds and they do their inspections, the CPK numbers that they get off the molded parts are typically better than what they expect because everything is basically the same. More often than not, our mold trials are one to two tests and then they are ready to ship. Of note is that about „ percent of our busi- ness, on average, is spare parts. This is because we can build the parts to the print and to the model with no hand-‚itting, and the customer can take that part, drop it right in the mold and be back up and running at …-percent cavita- tion. We also have mold designs that allow the customer to take the cavities and cores and the ejector pins out from the front face of the mold, and that allows them to get back up and run- ning far more quickly than pulling the whole mold out and being down for a day or two. But, it all depends on the customer. If the customer really puts an emphasis on staying in production, then there are things that we can do to make sure that we put them in the best situation to stay in production. Some of our customers also have requirements that the molds have the ability to run for …–„ million cycles before replacement, and we have been able to satisfy some of the toughest requirements to ensure long-lasting molds. Employees at Fairway Injection Molds run Yasda CNC machining centers in the company's hard- milling department. Fairway recently took delivery of a new Yasda YBM950V hard-machining center (pictured on the far right) to expand its ability to supply customers with very precisely machined parts, like shut-offs and other mold components, without the need for secondary handwork. FOR MORE INFORMATION Erowa Technology Inc. / 800-536-4894 / erowa.com MC Machinery Systems Inc. / 630-616-5920 / mcmachinery.com Yasda Precision America Corp. / 847-439-0201 / yasda.com

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