Unscheduled downtimes in production due to worn out or unserviced molds in machines can cause high costs and are a well-known problem for a lot of companies. In order to prevent these issues and optimize the use of their injection molds, a Swiss chocolate mold producer installed a predictive maintenance system via industrial RFID technology.
Maintaining oversight during frequent mold changes with RFID
Complex and expensive injection molds are typically used in manufacturing parts. Due to wear and contamination, they require regular cleaning, care and maintenance. The regularity often depends on handwritten records in a molds log-book, post-its or on the experience of the employees. In more modern companies, databases or excel sheets may be used to store this information. Regardless of the method, real-world experience shows that manual recording is often prone to errors. Maintenance and inspection are often only carried out if a mold malfunctions, when it tends to be too late.
Poured chocolate molds, that are used in continuous operation on the production lines of chocolate manufacturers, are known worldwide for their perfection and durability. In most cases, they are made in comparatively small batch sizes of 1500 to 2000 units. For this reason, the injection molds have a modular structure. The base is a master mold with exchangeable inserts which leads to quick and frequent mold change cycles. Additionally, there are certain things that require increased maintenance, like replacing hoses, lines or connecting components, that involve removing the master mold. This is why it is especially important to keep track of how many times a master mold has been used. A control system via industrial RFID technology can be installed to solve this problem.