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Profle 12 MoldMaking Technology August 2015 1 2 M o l d M a k i n g T e c h n o l o g y A u g u s t 2 0 1 5 Putting Design in the Driver's Seat By Matthew Danford Ameritech Die and Mold hasn't had any trouble keeping its lat- est robot busy. That's despite the fact that the system represents the shop's first effort to expand robot-tending beyond electrode machining and sinker EDM operations, both of which tend to require relatively frequent setups that justify automation. Steve Rotman, company president, credits this achievement to one factor above all else: the right production philosophy. It helps that none of the people working with the shop's automated equipment need convincing about the merits of this philosophy, Rotman adds. In fact, the right mindset has become so central to the shop's success that it has dramatically influenced how new employees are trained. What's more, the influence of this philosophy extends beyond the shop's core operations. It's also proven to be a key competitive edge for Ameritech Automation Systems, a new division that isn't even in the business of manufacturing plastic injection molds. What is this common philosophical denominator in these efforts to automate processes, develop the workforce and expand into new types of business? "We drive our moldmak- ing through engineering," Rotman says. Although Ameritech certainly isn't the only mold manufacturer that's adopted this approach, the shop stands out as an example of how wide- ranging the benefits can be. Engineering an Automated Process The basic idea behind engineering-driven mold manufactur- ing is to take advantage of principles more commonly seen in high-production operations—that is, to operate more like Automating electrode production and EDM is one thing, but Ameritech had to learn to design for automation to enable robot-fed machining of cores, cavities and inserts on its DMG MORI HSC 75 Linear fve-axis machining center. Images courtesy of Ameritech Die and Mold. Leadership Steve Rotman, co-founder and president Mark Rotman, plant manager, North Carolina headquarters Rusty Rotman, plant manager, Florida location Metrics Annual sales: $8 million No. of employees: 33 Average on-time delivery rate: 98.7% Average lead time: 10-12 weeks No. of molds built per year: 50 End Markets Automotive, appliance, consumer goods, military and aerospace, automation and assembly Products and Services • Design, manufacture of complex tooling with multiple actions • Two-shot, rotary/transfer and blow molds • Project management • Engineering changes/repairs • Mold sampling • Gundrilling services • Laser and micro-TIG welding services • Automation systems (Ameritech Automation Systems) • Aerospace and military components (Ameritech Die and Mold South) • EDM services Facilities and Equipment 26,000-square-foot NC headquarters: Machining: • DMG MORI: HSC 75 Linear fve-axis machining center w/Erowa robot • GF Machining Solutions: Mikron HPM 1350U 5-Axis VMC • Makino: V56, V55 high-speed VMCs, SNC64 VMC, KE-55 vertical knee mill • Enshu: 650 VMCs (2), 650EX VMC, 530 VMC • Fidia: K165 high-speed 3+2 VMC • OKK: 860 high-speed VMC, VP600 VMC • Kuraki: KBT 11 WDX.A boring mill EDM: • GF Machining Solutions: Charmilles Roboform 550, Robofll 440 (wire) • MC Machinery Systems: Ingersoll Gantry 1200 FP60 • Erowa: Robot multi, robot compact feeding EDMs • Chicago fast-hole EDM CAD/CAM: • Cimatron, AutoCAD, Surfcam, SolidWorks, Esprit, BobCAD/CAM wire • Surface grinding • Gundrilling • Welding (laser and micro-TIG) • Injection presses (500- and 250-ton) 18,000-square-foot Florida facility: Machining: • Mazak: Nexus 510 VMC (2), VTC 300 VMC, VTC 20B VMC • Fidia D 165 high-speed VMC • Creative Evolution high-speed mill • DMG MORI HMC EDM: • Fanuc Robocut A-1iE fve-axis wire • Makino EDNC 65 sinker CAD/CAM: • Mastercam X, Solidworks, Cimatron, Esprit Inspection: • Tesa DCC CMM • Starret Sigma HE400 optical comparator • MBC Rockwell tester • M4900cc conductivity meter • Injection presses (100-, 400-ton) • Grinding (surface, cutter, pedastal) • Sawing • Welding (TIG and ARC) welding Certifcations AS-9100B Affliations • Founding member, Apprenticeship 2000 • American Mold Builders Association Ameritech Die and Mold 107 Knob Hill Road Mooresville, North Carolina Phone: 704-664-0801 Email: info@amdiemold.com Website: amdiemold.com COMPANY: