The goals of the retrofit were to promote efficiency and ultimately extend the lifecycle of the molds and machinery. Reliability and ease of operation were also considerations as was a strong ROI. Eurotherm’s MACO® Compact HT Series controller, designed exclusively for Van Dorn HT injection molding machines, provided a reliable solution to help Metro Custom Plastics engineers reach those goals.
"User friendliness, reliability, overall component design, and a package that would meet the needs of production and operators were what we were looking for," said Thomas.
From a mess of wires to a streamlined process
Although the team said that the presentation of benefits was compelling and the Eurotherm technical team was well prepared for the installation, Guardiola admitted some reservations as the set up commenced. Worrying is part of a plant manager’s job description.
"At first, when they began to tear into the cabinet and wires were hanging out all over the place I was a bit skeptical; however, in the end, I was amazed that it went so smoothly," said Guardiola. "The installation crew was very professional and completed the installation on time. But in the end, it wasn’t how good it looked but how well it worked. And it worked great."
Thomas describes the installation as quick, professional, and efficient which was important because of Metro Custom Plastic’s production schedule. Many of Metro’s customers use JIT practices and delays could have been costly. "Startup went very well, and with just a few adjustments, we were ready to go," said Thomas. "Downtime had to be carefully planned as quick turnaround response to customer needs has always been a top priority for Metro Custom Plastics. We couldn’t afford to have the timing of this project overrun."
ROI: The value Eurotherm brought to Metro Custom Plastics
Eurotherm’s MACO compact controller has delivered multifaceted benefits for the Arlington, Texas based manufacturer.
"Improvement in low mold close/mold protection was dramatic over the original control resulting in a reduction in mold damage problems and the cost associated in fixing them," Guardiola said.
Production Benefits
-
Actual downtime has been reduced by double digit percentages
-
Improved production of up to 1 hour per day because of less downtime
-
Total machine productivity improvement is approximately five percent
-
On one part alone, cycle time went from 42 to 40 seconds, a 4-5 percent improvement
According to Thomas, “The ability to show problems through the control diagnostics is extremely helpful. It allows us to address problems quickly and get back in production.”
Additionally, the company has been able to reduce scrap by approximately 3.5 percent and significantly reduced the need for major maintenance due to better control reliability.
Quality Benefits
-
Consistent pressure, temperature, and positions over the production cycle provides uniformity in part quality, supporting Metro Custom Plastic customer’s expectations
-
Impact™ II process control on the MACO was a major improvement over the original OEM offering
Safety improvements
“Improving performance and reducing downtime extends the useful life of a good existing machine and makes the ROI entire package well worth the investment,” said Havel. He also added, “In these tough economic times, carefully choosing what and when to invest allows us to not only maintain our customer base but also to increase it with new business as it develops. Right now there an estimated 200,000 molds looking for a new home. We have the machines, people and process ready to take in a lot of new business."
Havel adds, “Since we are debt free and plan to remain debt free, we must continue to invest wisely to be a survivor. Customers will not sacrifice quality just because the economy is down. When potential customers visit our facility, presentation of the machines with these new upgrades shows our commitment to continuous improvement.”
Download the full Press Release
