Solutions

The Algoryx Mold Characterization Study results apply to all phases of the product life cycle: development, validation and production.

Product development teams use the Algoryx Mold Characterization Study analysis and simulation results to determine and confirm—in one and only one step—the changes necessary to all elements of the molding system in order to meet or exceed customer Cpk requirements. The molding system includes design targets, design tolerances, design GD & T, the mold, the press, the measurement system and the material.

Product validation teams use the Algoryx Mold Characterization Study results to reduce the cost of validation by greatly reducing the number of measurements, the number of SPC studies and the number of process capability studies required for validation. The greatly reduced number of measurements significantly shortens the time it takes to validate a mold.

Production teams use the Algoryx Mold Characterization Study results to reduce cycle time, to reduce energy costs and to reduce in-process inspection costs. The Algoryx Mold Characterization Study results can also be used as the foundation for process monitoring (accept/reject each shot) and process control (closed-loop feedback) systems.

The Algoryx Mold Characterization Study results apply up and down the entire supply chain including the OEM customer, the molder, the mold fabricator, the mold designer and the part designer.

The Algoryx Mold Characterization Study process integrates activities across engineering disciplines including design, tooling, process, quality, project and product engineering.

The Algoryx Mold Characterization Study process is a systems engineering approach to the molding system that includes design tolerances, design GD & T, the mold, the press, the measurement system and material.

The Mold Characterization Study process is the foundation for data-based decision-making and communication throughout the entire supply chain, whether local or global, internal or external.

Algoryx Eliminates Development and Validation Iteration Loops

Mold Development and Validation In Low and High Cost Countries Before Algoryx. Four iteration loops. Click to enlarge.	Mold Development and Validation In Low and High Cost Countries After Algoryx. No iteration loops. Click to enlarge.
These flowcharts are based on the premise that as much of the development work as possible is done in the Low Cost Country (LCC) and the customer and production are in the High Cost Country (HCC).

Algoryx supports your existing processes by eliminating all iterative tuning cycles (mold, design tolerances, press settings, GD & T and measurement system):

Identify the Predictor Dimension for the mold. When the Predictor Dimension is measured all other dimensions are known and not measured.
Eliminate destructive measurement.
Reduce the amount of Validation SPC and Cpk analysis by measuring only the Predictor Dimension (only one dimension in one cavity).
Identify the priority of design tolerance relaxations to preserve design integrity.
Determine the optimal press settings for the highest quality parts.
The Mold Characterization Study travels with the mold from press to press and is not press dependent.
Use the Mold Characterization Study to predict tool wear and schedule preventative maintenance.
Analyze the effects of material variation on dimensional compliance.
Monitor production processes using the Predictor Dimension instead of all in-process dimensions in all cavities.
Troubleshoot problem molds.
Identify & rectify bad data points.
and more … Take the Algoryx Challenge – See the results using your data!

Algoryx Simulates Changes without Cost or Risk

Algoryx’s Correlation Master software can be operated in two modes-analysis and simulation. Correlation Master is run in the analysis mode using “as is” conditions. This means Correlation Master is run using part data from the current (“as is”) mold, using current design tolerances, design targets, design GD & T and the current measurement system.

Correlation Master is run in the simulation mode to confirm team choices on tuning the mold and changing design targets, design tolerances, design GD &T and the capability of the measurement system. When Correlation Master is run in the simulation mode, it uses real part data from the last Induced Variation Study. This functionality is extremely important because it again means that Correlation Master is using real data from real parts made in real molds on real presses run by real people and measured by real measurement systems.

The primary purpose of running Correlation Master in the simulation mode is to confirm to the development team that their mold, tolerance, etc. changes result in good parts and in a mold that has the capability to deliver parts that meet or exceed customer Cpk requirements. It is important to note that this confirmation of mold capability is done with cost or risk.

The graphics below demonstrate how Algoryx simulates changes to two mold dimension. This simulation confirms that the steel changes result in a mold that produces good parts with Cpks that meet or exceed customer requirements.

Simulated Mold Output Before Algoryx- Click to Enlarge

Simulated Mold Output After Algoryx - Click to Enlarge

Take the Algoryx Challenge – See the results using your data!

Algoryx Saves You Time and Money

Algoryx Cost Savings for One New Mold (Development & 4-Year Production)

The above cost savings chart excludes:

Value of faster time-to-market.
4-5% cycle time reduction.
4-5% reduced energy cost.
Reduced assembly line down-time.
Based on industry-typical metrics.

Development Savings

Faster time-to-market.
Risk Mitigation:
- Data-based decision-making.
- Focus on the critical one dimension instead of the not-so-critical.
- Easily understood correlation charts.
- Fewer technical mistakes that delay delivery and increase costs.
- Simulation confirms choices.
Simulate and analyze optimal mold settings and eliminate mold tuning iterations.
Reduce travel expenses related to problem molds.

Validation Savings

Validation is mold specific, not press specific:

Validate by measuring only one dimension in one cavity.
Reduce the amount of Validation SPC and Cpk analysis by measuring only one dimension in one cavity.
Consistent part production across different presses and locations.
Mold specific & press independent validation insures optimal quality and cycle times while eliminating validation each time the mold is moved to a new production site. Identify if tool wear is a problem, and if tool wear is a problem, to identify, in advance, when you will start producing bad parts.

Production Savings

Lower part cost:

Reduce cycle times by 4-5%.
Reduce press energy costs by 4-5%.
Reduce shifts due to optimized cycle times.
Anticipate and account for material variations and tool wear.
Reduce travel expenses related to problem molds.