Research On Optimization Of Mold Replacement Operation For Z Production Line Injection Molding Machine Of Y Company

In recent years,with policy support,rising oil prices,and technological innovation,the new energy vehicle industry has developed rapidly.The production and sales of new energy vehicles in China have achieved synchronous growth,gradually eroding the market share of traditional vehicles.Traditional car companies,facing the impact of new energy vehicles,on the one hand,utilize brand and technological advantages to accelerate enterprise transformation,and on the other hand,accelerate technological innovation and product upgrading.The upstream suppliers of traditional car companies have to accelerate the turnover frequency of their production lines in order to compete for the market and respond to product updates.The equipment downtime caused by production line switching has become the main reason for low equipment utilization and slow enterprise response speed.Therefore,the main research purpose of this article is to apply rapid mold changing technology to shorten the time of device switching.In view of this,this article follows the research approach of case study comparative analysis and applies the rapid mold change method in lean production to study the mold change operation of Y company’s Z production line.Select the mold replacement process of Z production line of Y company,an automotive parts manufacturer,as the research object to improve the mold replacement process of injection molding machines.Firstly,by reviewing the original mold changing process of the Z production line,it is found that there were problems with its mold changing process and job content.Secondly,through on-site research and fishbone diagram analysis,the reasons for the problems occurred during the mold replacement operation are analyzed.Then,based on the single minute exchange of die(SMED)and combined with the mold changing operation process of the Z production line,the internal and external operations are reclassified,and the mold changing operation sequence is adjusted using the ECRS principle.Next,by simplifying the first article inspection process,eliminating waste in searching,and standardizing the parameter adjustment process,the equipment downtime can be reduced.Finally,the effectiveness of the optimization plan is verified by comparing the mold change operation time and relevant production indicators before and after optimization.In addition,it provides guarantee measures for how to implement a rapid mold replacement plan.Y Company has a problem of low efficiency in mold replacement operations,due to unreasonable workflow,cumbersome first article inspection,and long parameter adjustment time,which has resulted in low equipment usage and reduced production efficiency.Based on this,this article proposes an optimization plan based on the methods of rapid mold change and job time improvement.By verifying the mold change operation time before and after the improvement plan,the optimized plan reduces the equipment downtime by 45.66%,achieving the goal of shortening downtime,and improving equipment utilization,and production efficiency.The optimization plan in this article shortens the mold changing operation time of Y Company’s Z production line and improves the utilization rate of equipment.The method of setting up a mold heating zone to heat up the mold in advance provides new ideas for improving mold replacement operations in the same industry.In addition,the application of rapid mold changing operations on Y Company’s Z production line has also enriched the SMED rapid mold changing theory.