Nypro employees receive an array of training to create high-quality molds. |
Nypro Puerto Rico needed a change. The first offshore facility for the eighth largest injection molder was overhauling the mold building capabilities of the Nypro Technology Center (NTC). A complete shop upgrade—four new machine tools—was needed to grow and to compete for business in South America and the Dominican Republic.
Upgrading an entire shop floor is no small task. Installation and operator training can be demanding enough; the need for a smooth transition and a speedy return on investment adds to the challenge. Popular belief argues that a catalyst, or change agent, is needed to exact such substantial change. NTC chose Mike Cacio to play that role.
"We saw growth opportunities alongside competitive threats," says Cacio, manager of NTC. "We knew we could not reach our goals by merely adding mold builders or conventional machinery. We needed new machine tools and a new approach to mold building. The combination allows us to decrease cycle times, increase mold quality and change the rules."
Perfect Timing
During the planning stages of NTC's overhaul, the Puerto Rico Science and Technology Board launched a grant program to help promote industry research and development. Nypro Puerto Rico president Reynaldo Encarnacion worked closely with the government to secure a grant. After a two-year process, the effort paid off and NTC was awarded $2.5 million. Cacio immediately began searching for new technology.
"We put mold building technology under the microscope," says Cacio. "Our evaluation even included a review of technology used in Nypro's sister plants. We eventually chose a Makino SNC64 high-performance graphite-milling machine."
NTC then examined vertical machining centers along with wire and RAM sinker EDM technology. "We purchased a V55 high-performance vertical machining center, a U53K wire EDM and an EDNC43S RAM sinker EDM—all from Makino," says Cacio. "Working with one manufacturer on this project influenced our decision. While each machine meets specific application requirements, they each also have similar controllers. That makes operator training much simpler."
To ensure a smooth transition and to minimize downtime, the installation was done in phases, and an array of training was conducted. Operator instruction from Makino on each machine, as well as on high-performance machining techniques and preventative maintenance, was provided.
"Training is crucial to our success," added Cacio. "Having the finest technology is critical. Knowing how to maximize its potential is just as important."
The Skills to Succeed
On top of manufacturer training, NTC has established a certified apprenticeship program with two local schools. This helps address a tight labor market and provides talented operators. NTC also has its own training facilities and utilizes online training from Nypro. The end result: the majority of its employees are journeymen mold makers.
"As an added measure, NTC obtained programming and tooling support from a consultant," says Cacio. "The right combination of training and support ensured we did not miss a beat. NTC could not afford to slow down on jobs during installation."
Many of NTC's jobs for customers like Hewlett-Packard involve extremely complex and detailed molds. In fact Nypro, a decorated supplier to the healthcare industry, does work for customers including Baxter Healthcare, Pall Biomedical and Abbott Laboratories that requires tolerances so tight, conventional machines simply cannot make the molds.
Edwin Robles checks the status of a mold on the V55. |
EDM R&D
One of the first jobs on NTC's new equipment was a centrifuge shaft mold. A centrifuge shaft is a small, intricate device used in blood separation—polishing of any kind impacts its mold definition and surface finish. Prior to its overhaul, NTC could not build this mold.
"New technology affords us a new approach to jobs and enhances our research and development for customers," says NTC EDM operator Ramon Gonzalez. "The centrifuge shaft mold was an experimental design. Our ability to build it allowed the customer to take this enhanced product to market."
Using the U53K wire EDM, Gonzalez achieves finishes as fine as 7 microns. "The U53K cuts fast and clean. The angles we achieve on it are crucial to these medical molds."
On both EDM machines, Gonzalez conducts programming and mold setups. "We conduct lights-out EDM, doing set- up and programming so it can machine through the night, unattended," he says. "During the day, unattended operation allows me to do mold repair welding. We also program jobs while the machine is running."
Detail Oriented
On the EDNC43S, Gonzalez has reached a two-micron finish. "The sinker's ability to conduct Diffused Discharge Machining (DDM) using High Quality Surface Finish (HQSF) technology decreases polishing dramatically," he says. "Offsets and pickups are straightforward on the EDNC43S and electrode setup is convenient. I can do up to four setups at a time, depending on the mold. As a result, EDM cycle times shrink." The blood collection mold is a prime example (see Figure 1).
Polishing used to be the toughest element of this application. Now the finish and accuracy achieved on the blood collection mold reduces polishing by 65 percent.
Supporting its aggressive EDM program, NTC relies on the SNC64 to machine electrodes. "Our electrode throughput has increased," says NTC milling operator Edwin Robles. "In the past, we had to grind certain electrode details. Now the SNC64 mills multiple electrodes quickly and accurately. We keep the EDM machines busy. And with the vacuum enclosure there is no problem with graphite dust."
Robles also operates the V55 and notes the similarity in programming. "The move into high-performance milling and three-dimensional milling on heat treated tool steels was new to us," he says. "Having to learn only one control allows me to focus on the spindle RPM and feedrates for these new machining techniques. With its HSK spindle and shrink fit tooling, the V55 gets good finishes, accurate tolerances and fast cycle times on heat treated molds. In fact, if design permits, we conduct all finish machining on the V55 in a hardened state."
Mike Cacio uses Nypro's EDM capabilities as a competitive advantage for research and development with its customers |
The Scientific Method
While NTC updated its whole shop floor with new technology, it was only half of the upgrade. NTC is also exploring a Scientific Injection Molding (SIM) approach to mold building. SIM takes a holistic view of the application, eliminates variables and aims toward a consistent mold building process—from mold design to finished part.
"Mold building technology is only as strong as its application," says Cacio. "Typically you have to tweak a plastic injection machine to get high quality results from each mold due to inconsistencies. Using SIM, the mold is decoupled from the plastic injection machine. Based on the mold's design parameters, it can be used across any plastic injection machine with matching paramaters. Consistency, accuracy and repeatability eliminate the black art from mold processing."
NTC learned of this stringent approach from John Bozzelli and John Klees, two industry veterans who teach courses on SIM. It evaluates part design, mold construction and materials, as well as mold processing. Each element of the process is considered equally important.
Faster Delivery, Fewer Steps
NTC's overhaul updated its mindset and its shop floor for results that go beyond reduced cycle times and increased quality. "The improved quality of NTC's mold repair work has allowed us to quote mold building jobs," says Cacio. "Between mold repair and customer research and development projects like the centrifuge shaft, business is increasing. In fact, we are working on two expansions to add an additional 6,000 square feet to our operations to handle the work."
And with its aggressive plan well underway, NTC continues to look forward. "We are examining the impact a five-axis machine will have on eliminating operations and cutting lead time," says Cacio. "Complex molds benefit from two more axes and with properly designed tools we can eliminate the need for electrodes, EDM and polishing. We are always looking to optimize our applications further. Continued improvements, through tweaking applications, improves our performance and keeps us competitive."
And while some might consider NTC's plan massive or complex, Cacio feels the decision to overhaul the shop was a simple one to make.
"When your primary market is an island roughly the size of Connecticut, you quickly realize the importance of doing what it takes to compete on a global basis."
Source: Competitive Mold Maker,
Volume 6, Number 2
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