Production

The bottom line: increase productivity and reduce costs!

Reduce cycle time by 4-5% or more. A 4-5% reduction in cycle time equals eliminating the hard cost of one shift per week for 24/7 operations. Alternatively, a 4-5% reduction in cycle time equals a 4-5% increase in productivity.
Reduce energy costs by 4-5% or more as a result of the 4-5% reduction in cycle time.
Reduce in-process inspection costs by 99+%.
Eliminate the cost of automatic in-process measurement gages other than one gage for the Predictor Dimension.
Reduce the cost of in-process SPC and Cpk analyses by doing them only on the Predictor Dimension.
Identify in-process measurement and data recording errors (as opposed to x-sigma outliers) to reduce process tampering.
Increase productivity by eliminating blocked cavities on production molds.

Production Methodology

The Algoryx Mold Characterization Study results are summarized, for production purposes, in two numbers. The Operating Range is the equivalent of a producibility window. When the value of the Predictor Dimension is within the Operating Range, then you are guaranteed all part dimensions from all cavities are in specification. When the value of the Predictor Dimension is outside of the Operating Range, then you are guaranteed that one or more part dimensions are out of specification.

The Operating Target is the center of the Operating Range. When the value of the Predictor Dimensions is at the Operating Target, then you have the highest quality (as measured by Cpks), the lowest scrap and the lowest rework.

The value of the Predictor Dimension can be measured for each shot during production using a visual measurement system. When this is done, then each shot can be either accepted (good parts) or rejected (bad parts). Algoryx thus enables real-time monitoring of press output.

The observed value of the Predictor Dimension can also be used as the input into a closed-loop feedback system that uses the Operating Target as the reference point. The closed-loop feedback system adjusts press settings using the difference between the measured value of the Predictor Dimension and the Operating Target as the driver.

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

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.
Greatly reduced in-process inspection. Measure only the Predictor Dimension instead of all dimensions.
Anticipate tool wear before parts are impacted.
Meet and exceed customer Cpk requirements. Algoryx enables production of the highest possible part quality.
Reduce travel expenses related to problem molds.

Alternate Technologies

The Algoryx production methodology is more closely aligned with strategic customer requirements than cavity pressure sensors. Your customer is not buying cavity pressure versus time profiles or integrals. Your customer wants to buy parts that meet specification.

Algoryx has not observed any correlation between cavity pressure sensor data and dimensions with high enough correlation coefficients to be usable to ensure dimensional compliance within specification. Algoryx’s observations are based on multiple studies done on different molds run by different Algoryx customers. There may be exceptions to this general observation.

If one elects to use cavity pressure sensors in production, then it is substantially cheaper to use one cavity pressure sensor in the one mold cavity containing the Predictor Dimension instead of in all cavities. In this context, Algoryx can be considered an enabling and complementary technology to cavity pressure sensors.