Continuous Improvement-To Build a World-Class Mold Enterprise

Zhuhai Gree Daikin Precision Mold Co., Ltd. (below shorten to GDM) is a Sino-Japanese joint capital enterprise specializing in precision mold, with comprehensive proposals of equipments and technologies in both metal and plastics, to provide customers with one-stop service.

GDM adhere to the managing goal of high-efficiency and high-quality, and have passed ISO9001, IS014110, OHSAS18001 system authentication on Sept, 2021.

GDM’s quality principle is “To exceed customers’ expectation as the goal, to create the world-class mold enterprise”.

GDM never stop pursuing efficiency and quality and will always keep on this path. GDM have long carried out the activities of “Whole participation, continuous improvement”, and the numerous improvement projects start from “Every piece of paper and every drop of water”. Each staff is persistent to require their own keeping continuous progress and the way to achieve it is to fully give a play to everyone’s capability, personality and passion, to increase GDM’s power through everyone’s power.

GDM had customized corporate class Project No.1 (Mold 100% qualified), Project No.2 (shorten the lead time of mold manufacturing) and Project No.1-version 2.0 (Mold qualified to put into production by once trial).

1. Project No.1 (Mold 100% qualified)——It has been completed. The annual average export volume of GDM is about 55%, and the and there is scarcely any accidents caused by quality overseas as the risk is controlled before delivery. As we known, the core of mold quality lies in material and tolerance, therefore GDM had brought in advanced test instrument for material analysis, such as spectrum analyzer, defect detector, stiffness detector, etc., so that to control the most important material quality of mold in our own hand. With machining equipments based on brand of Makino and Mitsubishi, along with progressive machining experiences, reach the goal of all parts within tolerance.

2. Project No.2 (shorten the lead time of mold manufacturing)——Currently it is being continuously implemented. This project started in Oct 2021. The qualified rate was 15.6% (Data from Jan to Sept 2021) before launch, and it has been upgraded to 40.5% after this project carried out, with an increase of 24.9%. (Data from Oct 2021 to Dec 2022)

It is mainly through following measures to ensure improvement:

① Continue to divide the part into different classification of A (Difficult), B (Medium) and C (Simple) to have grade control. Make summary and analysis constantly for those parts classified in grade A and B for technical precipitation and formation of related standard, so as to be reference and comparison for the following fabrication of similar molds.

② Prejudge the part deformation in analysis stage and then do pre-deformation in design, so the final part deformation accords with drawing requirements. At the same time, summarize this pre-deformation data and form into database as reference for following fabrication of same kind of molds.

③ Continuously upgrade the database of historical issues and sum up those dies which could not reach the goal of Once-shipment into a standard or case database.

④ Continuously use the software of Moldflow2023、Autoform R10 version, DFM-PRO and PDW, etc. for part analysis in order to make analyzed the deformation data closer to reality. Reduce the error and omission from manual review by induction of checke analyzing software that the problem could be effectively indentified in the early stage. Set phased target for the accuracy of CAE analysis to improve its accuracy steadily.

⑤ Control the abnormality of outflow in the whole procedure of analysis, design, fabrication, assembly, trial, inspection to improve the pass rate of each process, which is consistent with policy of “Do things right once”.

3. Project No.2 (shorten the lead time of mold manufacturing)——Currently it is under continuous implementation. This project started in 2020, on the condition of manufacturing 10 big plastic molds and 14 parts (64 sets of sheet metal dies) at the same time . Before this project implemented, they take 151 and 154 days respectively. But during 2020-2021 by means of adjusting relevant management structure and establishing a task force for cost reduction and efficiency imrprovment etc. and manage the personnel effectively, it has shorten the period of mold fabrication to 111 and 120 days respectively, lead time reduction is over 20%. In 2022 it still proceeded to optimize the relevant measures, however we reached the bottleneck, still far away from the goal of 50%. Based on the actual condition, invest to upgrade the software and hardware, aiming to further shorten the delivery time by implementing IT automation (or semi- automation). So far, the hardware investment has been completed with total 5 sets of machines newly added which are Gantry, Five-axis, Vertical machining center. In terms of software, the analyzing software for CAE and DFM has been upgraded. For now, the system of production management is under transition and target to complete it in Oct 2023.

   Zhuhai Gree Daikin as a precision mold corporate, not only has the reputation from the brand of Gree and Daikin as cornerstone but also possess a long-term planning in terms of improvement of quality and delivery time. GDM is definitely your best choice, welcome your inquiry.