Mold ID

Page 1:Mold IDRFID ensures transparency in mold handlingMoldMold IDRFID ensures transparency in mold handling

Page 2:2With more than 90 years of company history behind it, BalluffGmbH is a globally leading sensor specialist and system provider.The full-range product line encompasses high-quality sensors andsystems for distance measurement and identification, sensors forobject detection and fluid measurement as well as top-of-the-linenetwork and connection technology. With 61 locations, Balluff has astrong presence on every continent. The corporate headquarters inNeuhausen a.d.F. is located near Stuttgart. Balluff stands for application-specific customer solutions, com-prehensive services, individual consultation and prompt service.Our staff of more than 2750 employees is committed to providingoutstanding service worldwide.

Page 3:www.balluff.com 3www.balluff.comMold ID 1RFID ensures transparency in mold handling 1Contents 3Mold ID – components 4Effects and Cost-effectiveness 5Application description 6Balluff GmbH 8Mold ID makes the use of injection molds traceable and ensurestheir optimal utilization. Each mold has to be clearly identified, be-cause all relevant data—such as drawing number, last maintenanceor service life—is saved to the mold and can be retrieved at anytime. This makes incorrect assignments and missing forms a thing ofthe past. Production cycles are also counted, which enables preven-tive maintenance of the molds. This extends the runtime and sup-ports reliable operation. It increases the productivity of the systemsand improves the efficiency. Ensure transparency with Mold ID.Mold ID – Transparency inMold HandlingOptimize the use of your injection molds.And enable condition-based maintenance.Mold ID is backed by an autonomous system. All machines can beupgraded individually, without the manufacturer and regardless ofthe location.Another plus: You can access the Mold ID system from anywhere inthe world using a standard web browser, smartphone or tablet PC.An app with functions protected by configurable passwords enablesaccess to the data directly on the mold by using Near Field Com-munication (NFC).The benefits to you■■ Recording of the production cycles by an autonomous system■■ All data is available directly on the mold via RFID■■ Optimum mold change by visualizing theinspection intervals■■ Through Mold ID ranging from time-based (preventive) tocondition-based maintenance■■ Worldwide access to the Mold ID system using astandard web browser■■ Can be integrated into higher-level systems (e.g. MES) usinga web service interface■■ Reliable – Balluff apps for access to the moldContents

Page 4:4Molds are subject to wear and tear and must be regularly maintainedas a result. The regularity of inspection often depends on the experi-ence values of individual employees or handwritten notes that arenot available to everyone.In many cases, therefore, maintenance and inspection are frequentlycarried out only if the produced parts no longer meet the requiredquality standards or if the mold malfunctions.The benefits to you with an autonomous Mold ID■■ Fewer unplanned downtimes as the result of− continuous counting of the shots− automatic documentation on the mold− visualizing the mold status− notice for the operator about the next scheduledmaintenance■■ Transparency through the level of use of identically designedmolds■■ Overview of all molds currently running on the machines, throughaccess to the systems over the company network via TCP/IP.■■ Mobile reading out of the documented mold data via smartphoneor RFID handheld, for example, during an audit or when selectingthe correct mold.Mold ID makes the mold usage transparent and creates the pre-requisite for optimizing processes and monitoring your service andmaintenance.Mold0709Preheating stationProduction of plastic parts ininjection molding machinesWarehouse with injection moldsInspection and, if necessary,maintenanceof the injection moldsMold ID – componentsData carriers■■ For each mold■■ Variant depends onthe ambient conditionsShot counterVia inductive sensorfor communication withthe data carrierRFID unitFor communication withthe data carrierMobile end devices■■ Read data■■ For initializing data carriers■■ For setting limit values■■ For password protectionMold ID unit■■ Industrial PC■■ Software■■ Gateway to thecompany network■■ Visualization with theSmartLight signal lightTypical circulation of the toolsMold ID – components

Page 5:5www.balluff.comMold ID ROI calculationInformationNumber of machines 25 QuantityNumber of molds 120 QuantityHourly rate of the machine 65.00 €Costs for one employee per hour 35.00 €Duration in minutes for the documentationafter changing molds 5 min.Mold changes per day and machine 3 ×Expense for maintenance of a mold 5 hoursNumber of preventive maintenancecases per year and mold 6 ×Savings through shot-number-dependentmaintenance instead of preventive, time-based maintenance 1 ×ROI calculation V1 – Documentation V2 – Downtime V3 – Maintenance V4 = V1 V2 V3ROI = Investment in € €125,282.50 €125,282.50 €125,282.50 €125,282.50Savings in € per year €54,687.50 €85,937.50 €21,000.00 €143,395.83Amortization after 3.44 years 1.46 years 5.97 years 0.87 yearsInput fieldResult/fixedEffects and Cost-effectivenessThrough the automatic documentation of the shots and the notesconcerning timely maintenance of the molds, a Mold ID systemcontributes to the increased efficiency of injection molding machinesand molds. This has a positive effect on your key performance indi-cators – for example, on the OEE (overall equipment effectiveness).This is because Mold ID ensures the availability and quality of themolds.Contact usYou can receive a white paper about Mold ID and an customized,non-binding calculation of Mold ID usage with your numbers at nocost by writing to this address: mold-id@balluff.deWe look forward to your inquiry!The sample calculation of amortization time or ROI (return oninvestment) on this page shows that different criteria influence theprofitability. Therefore the various areas are calculated separately(V1 to V3). Taken as a whole, it becomes apparent that the invest-ment in Mold ID pays off after a short time and saves money (V4).ResultTime for documentation on one day 375 min.Documentation effort in one year 93,750 min.Costs for the documentation per year 54,688.00 € (V1)Savings per machine:Reduction of the unplanned downtime0.25 hoursSavings per day 343.75 €Savings per year 85,937.50 € (V2)Time required for preventive maintenanceof the molds today 3600.00 hours/yearSavings through shot-number-dependentmaintenance 600.00 hours/yearSavings for maintenance 21,000.00 € (V3)One-time investment 125,282.50 €Effects and Cost-effectiveness

Page 6:6■■ Attachingdata carrier■■ Specifyinglimit values■■ Defining names■■ Writing todata carrier■■ Shotcounter■■ Detectingmovement■■ Responseto system■■ RFID■■ Data fromthe system■■ Writing to the datacarrier on the mold■■ System■■ Comparingdata■■ Updatingthe status■■ Activation ofSmartLight■■ Readingout data■■ Defining newlimit value■■ Writing data todata carrierInitializing Counting Writing Comparing ResettingOne-time Cyclical MaintenanceInitializing■■ Attaching data carriers: The data carriers are attached to themold taking into account the installation instructions. Adhesive orscrew-on designs can be selected to match the mold (size, ac-cessibility, machining options, etc.).■■ Defining limit values: You can define the limit values for therespective mold. This requires defining two values:− Number of shots until the next instance of maintenance (redlamp)− Number when to issue a warning (yellow lamp)■■ Defining names: A unique name can be assigned to the mold,for example, the mold or drawing number supplemented by onenumber. This enables molds of the same design to be differenti-ated from one another.■■ Writing to data carriers: The data carrier is written with thepreviously defined limit values. Additionally, the shot counter forthe mold is initially set to "0". This value can no longer be reset.Cyclical■■ Counting: Each production cycle (shot) is detected by the sensorinstalled on the machine. The number of edges that belong to ashot can be configured with the software. The counted edges arereported back to the system.■■ Writing: The system records the data and writes the informationdirectly to the data carrier on the mold. This ensures that no infor-mation is lost when the mold leaves the machine. Then the datacarrier contains the actual values—not estimated planned valuesfrom the ERP system.■■ Comparing: The system monitors limit values andvisualizes the status via SmartLight. If the shot counter is withinthe defined values, the lamp lights up green. The system switchesover to a special display mode if the value for the "Warning" isreached. The lower part of the lamp remains green. The upperpart is incrementally filled with yellow. If the maximum value isachieved, the lamp turns red.Maintenance■■ Resetting: If the mold reaches the previously defined limit, mainte-nance or repairs are performed on it according to the schedule.Before it can be used again, the limit values have to be adjustedand written back to the data carrier. The counter for all parts pro-duced with this tool cannot be tampered with. The limit values forwarning and maximum can be individually defined.Application descriptionThe functions of Mold ID can be divided into various phases. Examples ofthese phases are shown here.SmartLight signal lights for displaying operating statesA moldwas detectedWarning level Maximum levelexceededMaintenancerequiredNeutralstatusSelf-diagnosticsExplorerstatusNo mold detectedin the systemTechnicalerrorApplication description

Page 7:www.balluff.com 7www.balluff.comOverviewDetailed information aboutthe mold and the systemWith a smartphone youcan read out the data directlyon the mold usingNear Field Communication(NFC) and the Mold ID app.

Page 8:www.balluff.comHeadquartersBalluff GmbHSchurwaldstrasse 973765 Neuhausen a.d.F.GermanyPhone 49 7158 173-0Fax 49 7158 5010balluff@balluff.deDoc. No. 920549/Mat. No. 244699 ENA15; Subject to modification.Object DetectionLinear Position Sensing and MeasurementCondition Monitoring and Fluid SensorsIndustrial IdentificationIndustrial Networking and ConnectivityAccessoriesSystems and ServiceBalluff GmbH