ToolingDocs Case Studies

MCA Case Study #05-01-13


ToolingDocs was recently called in to provide a Maintenance Capability Assessment (MCA) for a proprietary molder. Below is an overview of the company along with:

  • Specific objectives expressed to ToolingDocs prior to the MCA
  • Scoring the department in 50 categories and 7 Key Performance Indicators
  • Final observations, recommendations and conclusion.

Company Overview

  • Company: Foreign (Proprietary)
  • Product Type: Communication devices
  • Production Environment: Production monitoring software, A/C’d
  • Average Daily Cavity Count: 102
  • Average Daily Cavity Efficiency: 90-95%
  • Mold Metrics: 53 active, mostly class 101, 4 to 8 cavities, 90% hot runner, avg. age 1-2 yrs
  • Presses: 17 total from 80 to 200 ton, avg. age 1-2 yrs.
  • Resins Run: PE, PP Acrylic, ABS, Styrene
  • MPP (Mold Pull Pace): 2-3 per day
  • Shop Metrics: 6 full-time repair technicians (2-day shift, 1-2nd and 1-3rd shift)
  • Shop Layout: 20’ X 60’ (1200 sq ft)
  • Documentation System: Manual worksheets & history files.

Administrative Objectives

Company Objectives:
How do we compare with others in the industry in terms of mold maintenance capability to implement a comprehensive PM program? 

Shop Supervisor Objectives:
What is required for our shop/staff to be able to perform as expected when servicing our molds?

MCA Observation summary

Shop Metrics: 
Adequately sized, new and clean shop. Not enough mold benches. Machinery (mills, surface grinders) adequate but not organized. P/C available but using a paper system for documentation. Adequate lifting capacity for molds but using an “A-frame” style hoist.

Documentation Metrics Overview:

Data Collection Methods & System:
Mold cycles being monitored manually by production staff. No attribute or dimensional data being gathered or tracked.

Data Utilization Practices:
Mold cycles captured but only utilizing them for timing of PM’s. No defect targeting, mold performance or maintenance analysis conducted.

MCA Conclusions and Recommendations Summary

This new, clean and well staffed facility has most of the hardware to implement a comprehensive PM program. However, they lack the most crucial tool used in achieving the optimal goal and that is due to the fact that there is no electronic capturing and utilization of data in the understanding of costs to proactively attack issues. Shop staff skill levels and experience were adequate, but there is no plan for continuing education and advancement of less experienced technicians.  

Shop metrics would improve by installing a bridge crane and purchasing two more mold benches. Data collection method was much better than most simply because of the dedicated clerk. Implementation of software will improve data utilization and provide the necessary information to target unscheduled mold stops along with most frequent or costly mold or part defects. Projected savings: 10% labor savings with improved mold reliability; estimated total is $70,000.00 min. over two years.

Final Scores and Shop Designation Level