CPL Mold, Tool & Die Making supplement June 2015

June 2015

Canadian

MOLD,TOOL &die making

WANTED: young people (But there’s some good news about the skilled worker shortage. Finally)

Do generic maintenance standards work?

MOLDMAKING, SHOP FLOOR COMPONENTS What’s new, now

MARKET OUTLOOK What to expect in the year(s) ahead

How to spend $10 million the smart way: CUTTING-EDGE TECHNOLOGIES reinvents itself

A supplement to

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©monkeybusinessimages/Getty Images/Thinkstock Background photo: ©SafakOguz/Getty Images/Thinkstock

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Can we plug the skills gap in time?

nce upon a time, shop class was mandatory in most high schools. There was a belief that even if a student wasn’t intent on becoming a mechanic or carpenter, having some basic life skills in these areas wasn’t a bad thing. And even for those who weren’t sure, this familiarity made it more likely — and easier — to fall into a skilled trade if events broke that way.

Over time, however, shop began to look dated and irrelevant and was given less status. Somewhere along the way, it was drilled into students that the only way to get ahead in life was to go to university and earn a degree. Occupations such as plumbers and pipefitters were looked down upon. They were the bedrock of blue-collar careers and thus commanded little respect. The people who made the big bucks wore white shirts and ties and owed their well-paying jobs to the institutions of higher learning they attended. Kids and parents were told that in the future, most jobs would require a BA degree at bare minimum.

We’re now dealing with the fallout from this ivory tower preoccupation. Today, Canada produces more university and college graduates, per capita, than most countries in the world, but has an acute shortage of workers who actually, you know, build and fix things.

The numbers are sobering. According to the Canadian Manufacturers & Exporters industry association, by 2016, Canada will have 1.3 million skilled labor jobs sitting vacant because there’s no one to do them. In the construction industry alone, there will be 219,000 workers retiring between now and 2020 and not nearly enough people to take their positions.

The good news? Canada’s mold, tool and die making industry is rolling up its sleeves to address the problem. The Greater Essex County District School Board (GECDSB) in Ontario now offers a Technical Education program that appears to be catching on among high school students, some of whom are earning up to $35,000 a year to learn a trade. Enrolment in the program’s manufacturing segment has grown by 17 per cent. Windsor’s Reko International Group is providing training, tools and molds, and hires four precision metal cutting program students at a time through the Ontario Youth Apprenticeship Program — and since the announcement of Reko’s partnership, GECDSB has so far received 19 inquiries from other local companies to get involved in something similar. Or consider George Brown’s new 14-week Mechanical Techniques program, which gives university engineering students lessons in machining, welding, CAD/ CAM, programmable logic control, and CNC machining techniques.

And in April, 20 youth graduated from the Canadian Tooling & Machining Association’s 32-week Introductory Trades Training program learning tool, die, mold, and machining skills. (See story on pg. 4.)

Given that the mass retirement of Baby Boom-era workers will only accelerate, it’s anybody’s guess whether or not the rise in enrolment in trades schools will be enough to tackle the dangerous skills chasm that needs to be bridged. But it’s a hopeful sign. And if enough of these young people actually transition into the moldmaking industry, you might just walk into a tooling shop a few years down the road and find — with all due respect to the Boomers who built so much of this industry — that it looks a little less like a Woodstock reunion.

contents

4 News 7 Industry Outlook: The road ahead Will the softening Canadian economy weaken the mold, tool and die making sector?

10 Technology Tips: Do generic maintenance standards work?

12 Company Profile: Cutting-Edge Technologies A new era begins for an Oldcastle tool shop

13 Moldmaking/Shop Floor Components: Here’s some of what’s new, now

Mark Stephen, editor Canadian Plastics

A supplement to

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news First graduates of the ITT program set to enter the workforce On April 28, 20 youth graduated from the Canadian Tooling & Machining Association’s 32-week Introductory Trades Training program learning tool, die, mold and machining skills.

This program was designed by the CTMA and its member companies to address youth unemployment in Windsor and Essex County as well as the skills shortage in the tool, die, mold and machining industry. Assistance was provided by New Beginnings and the Windsor Employment Assessment Centre.

In September 2014, youth participants received four weeks of introductory training at the Valiant Training & Development Centre, which was followed by a 28-week job placement with one of the following Windsor-Essex area companies: Advanced Machining Services Inc., Bolzano Tool & Die Ltd., Cavalier Tool & Manufacturing Ltd., Centerline (Windsor) Limited, Crest Mold Technology Inc., Electromac Group, Exact Laser Measurements Inc., Glider Guard Tool and Die Inc., H. Beck Machinery Ltd., J & C Tool & Die Limited, Jahn Engineering Ltd., JFK Systems, Kapco Tool & Die Ltd., Manor Tool & Die

Congrats to the first ITT graduating class.

Ltd., Sigma Engineering, and Technicut Tool Inc. The graduating youth, aged between 18 to 29, have gained new skills through in-depth, on-the-job training, all while being paid an hourly wage. Funding from the Ontario government through the “Ready, Set, Work” program and the Youth Employment Fund helped employers offset their costs of training throughout the program.

The CTMA has received a new round of funding from the Ontario government to enable it to offer this program to 75 more youth through three intakes — the first took place in April, and final two are scheduled for June and October 2015.

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KOMET Canada and Castelar Tool now share one location Two Ontario tool shops have now moved in together.

As of April, KOMET of Canada Tooling Solutions and Castelar Tool are sharing a 2,230-square-meter, state-of-the-art facility in Mississauga, Ont. The facility is larger than the former Castelar Tool and KOMET of Canada buildings combined, and features modern design and aesthetic, as well as eco-friendly and energyefficient features. The two companies already work closely together — Castelar Tool became KOMET’s first service partner in Canada two years ago — and will now pursue a more

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immediate collaboration.

“We are very excited for this milestone in our company’s history,” said Renato Evola, owner and president of Castelar Tool. “Our business has been growing for years, especially since becoming a KOMET service partner. However, we outgrew our space, and it was time for new home.

This new facility is much larger, and its completely refurbished interior is a pleasure to work in. With the increased capacity and productivity, we can serve our customers’ needs better than ever before, and we still have room to grow when that time comes.”

The new facility features Caste-

lar Tool’s production plant, as well as offices for both Castelar and KOMET of Canada’s headquarters.

Additionally, there is space for meetings, conferences, and training. The facility also has a lighter carbon footprint than the former Castelar facility, Evola said, featuring eco-friendly lighting and HVAC systems, and building heat recovery systems that will recycle heat generated by the machines on the production floor. As in the past, Castelar Tool has noteworthy production capabilities, with multiple Walter five-axis CNC tool grinders, an AGIE Wire EDM cutter, and a Haas vf4 CNC mill.

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news CWA Foundation introduces new funding program for welding The CWA Foundation has introduced the Secondary and Post-Secondary Institution Equipment and Funding Support program to improve the quality of welding facilities across Canada.

Teachers from welding programs within schools across Canada have the opportunity to apply to receive equipment and funding. This assistance will aid in the improvement and expansion of existing welding programs, and create new welding programs for schools that require them.

“Many institutions across Canada don’t receive the necessary funding that’s needed in order to provide Canadian students a safe, valuable welding experience,” said Deborah Mates, executive director of the CWA Foundation. “The CWA Foundation has created the Secondary and Post-Secondary Institution Equipment and Funding Support program to ensure that each institution has the resources they need.

The institutions will be able to enhance the welding experience for

Aalbers Tool & Mold invests and grows Oldcastle, Ont.-based moldmaker Aalbers Tool & Mold Inc. has partnered with the government of Ontario in a bid to grow its business and create 33 new jobs.

With almost $1 million in support from the Southwestern Ontario Development Fund, the company is investing in new state-of-the-art machinery and employee training that will enhance productivity and competitiveness. Aalbers designs and manufactures precision components for the automotive and consumer goods industries.

The project will help the company pursue new opportunities in Ontario’s growing aerospace sector.

Aalbers currently employs about 106 workers.

“The investment we’re announcing builds on our more than 30 years in business at Aalbers,” said CEO Gary Aalbers. “This new equipment and the resultant technical training further enhances our employees’ technical capabilities and competitiveness, coupled with offering reduced lead times and advanced flexibility to our customers. Along with that, is the opportunity to further strengthen and enhance our workforce, as the new equipment will not only offer a wider range of opportunities for Aalbers, but also open new and exciting opportunities to develop our business with new industry sectors.”

Modeled on the Eastern Ontario Development Fund, the Southwestern Ontario Development Fund is designed to help to create jobs and diversify the economy by encouraging regional businesses to pursue innovation and new markets. Together, the Ontario government said, these two funds have created and retained more than 29,000 jobs and attracted more than $1.25 billion in investment.

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students by creating an attractive program while upholding all safety requirements.”

Teachers from secondary and postsecondary institutions can download the application directly from the CWA Foundation website.

Headquartered in Milton, Ont., the CWA Foundation is a not-forprofit division of the CWB Group.

It was formed as a national membership-driven association, mandated to promote and support the welding and joining industry in Canada.

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GM Canada to cut 1,000 jobs at Oshawa, Ont. plant GM Canada will cut about 1,000 positions in Oshawa, Ont., as it confirmed that the end of production for the Chevrolet Camaro at Oshawa Assembly will be November 20, 2015. This production move was first announced in December 2012.

Currently, the Oshawa Assembly manufactures six vehicles: the Chevrolet Impala, Chevrolet Camaro, Buick Regal, and Cadillac XTS on its “Flex Line” (currently on three shifts), as well as the Chevrolet Equinox and the Chevrolet Impala Limited on the “Consolidated Line” (currently on one shift).

After November 20, 2015, Oshawa Assembly will continue to produce five vehicles. The majority of all industry assembly plants in North America currently run on two shifts.

“GM Canada will continue to examine a range of long-term opportunities and competitiveness enhancements for Oshawa Assembly, working with Unifor, government, supplier, and community partners to ensure our operations are as innovative, efficient, and costcompetitive as they can be,” the company said in a statement. “Future product decisions will not be made until after Unifor national bargaining, scheduled for 2016.”

According to GM, it still remains committed to Canada, which is the company’s fifth largest country market globally for auto sales and also for vehicle production. GM recently announced more than $800 million in new investment in its CAMI facility in Ingersoll, Ont.; and in April, it announced that its Canadian Engineering Centre, located in Oshawa will expand as an innovation hub for “the connected car” and green technologies.

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news Magna sells interiors business to Spain’s Grupo Antolin for $525 million Automotive parts supplier Magna International Inc. is selling its interiors operations to Spanish auto parts manufacturer Grupo Antolin for approximately US$525 million.

The transaction, involving the production of headliners, interior trim panels, instrument panels, and other interior components, includes 36 manufacturing operations and approximately 12,000 employees located in North America, Europe, and Asia.

In a statement, Magna said the deal — which represents about a tenth of the company’s total global work force and about US$2.4 billion in annual sales — is part of its strategy to refine its product lineup to focus on key areas of automotive vehicles. Magna’s seating and lighting businesses are not included in the deal.

“We are confident that Grupo Antolin will continue to serve our interiors customers and provide to our interiors employees a solid foundation for the future,” Magna chief executive Don Walker in the statement.

Headquartered in Aurora, Ont., Magna is Canada’s largest auto parts supplier, and one of the largest in the world. It currently has 313 manufacturing operations and 84 product development, engineering, and sales centres in 28 countries.

Grupo Antolin has about 14,800 employees and a presence in 25 countries. The company reported 2014 annual revenue of 2.225 billion euros (US$2.38 billion).

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CEO of auto supplier Uni-Select retiring after 17 years The head of Uni-Select Inc. is retiring this summer after 17 years with the auto parts supplier, the last seven as president and CEO. Chief operating officer Henry Buckley, who was hired last fall, will take over from Richard Roy effective August 1, the company said.

The change in leadership Henry Buckley comes as the Quebec-based company is preparing to close the sale by June of its U.S. parts distribution operations to an affiliate of Icahn Enterprises for US$340 million.

Announced in February, the deal includes Beck/ Arnley Worldparts, 39 distribution centres, and 240 corporate stores that employ nearly 3,000 people.

Following the sale of its U.S. business, UniSelect intends to strengthen its Canadian operations and FinishMaster, a distributor of automotive paints and coatings in the U.S. MT&D

PEOPLE Michael Christodoulou has been appointed as president and COO of Mississauga, Ont.-based Walter Surface Technologies.

Stefan Fickenscher has been named the new managing director of Trumpf Canada. He succeeds Stefan Schreiber who returns to Trumpf GmbH + Co. KG in Ditzingen, Germany as head of central sales subsidiaries in the machine tool division.

GF Machining Solutions, headquartered in Lincolnshire, Ill.,

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has named Scott Fosdick as its new head of market region, Americas.

Methods Machine Tools Inc., headquartered in Sudbury, Mass., has named Don Miller as general manager of its operations in Elgin, Ill. Joe Poulin has joined Oakville, Ont.-based Elliott-Matsuura Canada as regional sales manager. Poulin has 15 years of experience in the machine tool industry and most recently served as sales manager for Canada, for Hurco Companies.

Michael Christodoulou

Stefan Fickenscher

Don Miller

Scott Fosdick

Joe Poulin

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industry outlook

The

©edel-fotografie/Getty Images/Thinkstock

ROAD AHEAD

By Mark Stephen, editor Remember all that talk a few years back, as we came out of the Great Recession, about a double-dip that might send us back into the economic sewer head-first? Turns out it was about as real as a modern-day Elvis sighting.

The double-dip never materialized and times got a lot better for many Canadian plastics processors, and for the mold, tool and die makers working with them. The automotive sector turned red hot thanks to pent-up, post-recession demand; and the housing sector took off, as cities like Toronto and Vancouver experienced unprecedented condo booms.

But that was a few years ago. Fast-forward to mid2015, and signs of trouble are creeping in. Nobody is hitting the panic button just yet, but Canada’s economy is softening, as the plunge in oil prices takes its toll on everything from exports to government finances. In its May 2015 forecast, Capital Economics, which is on the gloomier side of projections, predicted Canada’s economy will expand by just 1.5 per cent this year and 1 per cent in 2016. Other economists have also cut their forecasts, though they’re not as bleak. The Bank of Canada has also warned of the slower pace, going so far as to cut its benchmark rate in a surprise January move, while the hit from oil is also showing up in monthly jobs reports:

Talk about a speed bump: Canada’s economy is slowing, as the plunge in oil prices takes its toll on everything from exports to government finances. But will it put the brakes on the mold, tool and die making sector?

The Canadian economy lost 19,700 net jobs in April, according to Statistics Canada.

Canadian oil producers will be hardest hit, losing an estimated US$40 billion in revenues this year, according to the Conference Board of Canada — which will take a definite toll on business investment and corporate profits, the board said.

However, Canada’s manufacturing sector, centred largely in Ontario and Quebec, will benefit from what the board called a “cocktail of positive factors,” including rising productivity, a lower Loonie, and a stronger U.S. economy — all of which will translate into higher profits and, eventually, increased investment in equipment to boost capacity. The potential fly in the ointment? “Canadian companies will be hard-pressed to compete with U.S. manufacturers in emerging markets, where young and sophisticated consumers want global brands,” the board cautioned.

PLUSES AND MINUSES So what’s it all mean for Canada’s mold, tool and die makers? It helps to get a sense, first, of where the sector is right now. But that’s easier said than done, since the available statistics are always a year or two past their

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industry outlook best-before dates. For what they’re worth, slightly dated statistics from Industry Canada indicate there were an estimated 464 Canadian establishments with 5,616 employees that made industrial molds in 2012 (the most recent year for which figures are available). This was down significantly from the pre-recession era. In 2005, for example, Industry Canada counted 579 firms making industrial molds. Industrial moldmakers shipped an estimated $959 million of their products in 2012 (down from 2004 when $1.51 billion in shipments were recorded). The U.S. took in about three-quarters of Canadian industrial mold exports in 2012.

Three years later, one recent bit of bad fiscal news — the Canadian dollar dropping like an anvil — is widely hailed as a good thing by mold, tool and die makers.

“The low Canadian dollar relative to the U.S. dollar gives moldmakers a competitive advantage if the customer, and competition, is American,” said David Palmer, sales manager at Windsor, Ont.-based Build-A-Mold and chairman of the Canadian Association of Mold Makers (CAMM). “A Loonie hovering around 80 cents is ideal — not too high and not too low. And we certainly don’t like to see a fluctuating situation, with the dollar rapidly gaining or losing in value against the U.S. dollar within a short period of time.”

A second headache for the economy in general that’s turning into a blessing for the moldmakers is the low price of oil — never a bad thing for companies that make things out of plastic. Plastic is a key element in light-weighting vehicles for fuel efficiency, which is more important than ever given government fuel economy regulations like the looming Corporate Average Fuel Economy (CAFE) standards in the U.S. The CAFE standard will be 35.5 miles per gallon by 2016 and a whopping 54.5 miles per gallon by 2025, pushing auto makers to improve fuel efficiency in new and innovative ways. Light-weighting, and the growing use of plastic body parts in vehicle manufacturing, is a reminder of the close ties between the mold, tool and die sector and the automotive industry — as is CAMM’s announcement in January 2015 that it had entered into a “collaborative working relationship” with the Automotive Parts Manufacturers’ Association. The two Canadian groups will work together on advocacy, trade missions, and special events.

Not that anyone could forget the importance of the automotive industry to the moldmakers — or that the health of the first largely dictates the health of the second. According to the Paris, France-based Interna-

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tional Organization of Motor Vehicle Manufacturers — known as the “Organisation Internationale des Constructeurs d’Automobiles” or OICA in French — a total of 2,379,000 vehicles were made in Canada in 2013, a drop of 3.4 per cent from the year before. By contrast, 11,066,000 vehicles were made in the U.S., an increase of 7.1 per cent. OICA figures for the first half of 2014 offer much of the same. A total of 1,186,000 vehicles were made in Canada during the first six months of 2014, a 1.8 per cent dip, while 5,943,000 vehicles were made in the same period in the U.S., a 4.7 per cent increase.

But that might change for the better in Canada going forward. Sales of new cars and trucks climbed 5.7 per cent in April 2015 compared to a year ago, making it the best April on record for Canadian auto makers, according to a new report from Toronto-based DesRosiers Automotive Consultants. Canadians bought 189,072 vehicles in April, despite economic concerns in Western Canada stemming from low oil prices. “The economic challenges facing Alberta and Saskatchewan have not seemed to impact national sales,” DesRosiers said in its report. Year to date, sales are up 3.7 per cent to 557,645 vehicles, with General Motors leading the pack with its sales growing 14.5 per cent compared with April 2014, to 29,127 vehicles.

“Overall, automotive demand has levelled off after running very hot for the past two years,” said Mike Hicks, vice president of DMS Canada Ltd., in Oldcastle, Ont. “The extreme push has gone past and production is now relatively stable, which is a big improvement over the recession years, when vehicle manufacturing bounced up and down like crazy. We’ve lived and died with the auto sector, and now we appear to be in a good cycle for the next five years or so.”

RETHINKING RESHORING And if all is relatively well with the auto sector, the same can almost be said when it comes to the mold, tool and die sector actually getting paid on time for its automotive-related work — which has definitely not always been the case. “I would say there’s been improvement in getting paid by Tier One and Tier Two suppliers,” David Palmer said. “For example, Build-a-Mold has done direct business with Ford Motor Co., and we are on a progressive payment plan with them. We get a level of payment with the purchase order, a level of payment at tool-build, and final payment when everything has been delivered and signed off. These regular fees mean that our com-

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industry outlook pany isn’t out of pocket for a year-and-a-half.”

But the dreaded PPAP terms remain the norm for contracts with the Big Three auto makers. Under PPAP — which stands for “Production Part Approval Process” — all components from suppliers must meet exacting standards before being approved for use in an OEM’s production line. This means that suppliers don’t get paid until all their parts are approved, which can take months, if not years. “OEMs love to follow PPAP because it allows them to hold onto their money longer,” Palmer said. “Some mold shops have been able to work around PPAP terms, however, by negotiating a progressive payment schedule.”

And as payment styles are beginning to improve, the threat level from foreign competition — which was at one point basically a dagger aimed at the tooling sector’s heart — seems to be dropping. It’s almost impossible to read a newspaper or watch the news these days without coming across a report of a renaissance in North American manufacturing. “Reshoring” is indeed the buzzword on everyone’s lips lately, and there’s plenty of evidence to suggest the phenomenon is, in fact, real. A new report by KPMG reveals that Canadian companies are increasingly turning away from offshoring as a cost-saving solution. “In 2014, only 14 per cent of manufacturers planned to source from China, compared with 31 per cent in 2013,” the report said. “Likewise, plans to source from India were at three per cent this year compared to 12 per cent last year.”

But that doesn’t mean the work is returning in droves.

“They’re still building tools in China, but it doesn’t have the same pull that it used to,” Mike Hicks said. “With the investment in new technologies like CNC machine tools and developments like high-speed, lights-out operations, Canadian mold shops are bringing costs down and bringing some work back home. It’s not a tidal wave, but it is happening.”

And it definitely doesn’t mean that all the work is landing on Canadian shores. As a recent Supply Chain Optimization study by the Hackett Group pointed out, “few of the low-skill Chinese manufacturing jobs will ever return to advanced economies; most will simply move to other low-cost countries.” And by “low-cost countries”, it means Mexico. And that goes for molds, tools and dies, too.

“Mexico is becoming the new China, but I still consider this an acceptable development for Canadian and American toolmakers because it allows us to react to demand in a better manner,” said David Palmer. “Numerous tool shops in Windsor, for example, now have satellite operations in

Mexico, and there is huge demand for parts suppliers to have operations in Mexico to satisfy the Ford, GM, Volkswagen and BMW plants already in that country. The Tier One suppliers — our customers — require nearby tools shops to satisfy not only the tooling demand, but also any engineering changes and repairs.”

A final, greater concern — stop us if you’ve heard it before — is the looming shortage of skilled workers due to a rapidly aging workforce and a lack of replacements.

“I’d put the average age of a moldmaker in Canada at about 50 years old,” Palmer said. “We need to rejuvenate our workforce. CAMM has worked closely with St. Clair College in Windsor, and worked very closely with apprenticeship programs, to encourage young people to consider careers in mold, tool and die shops. It’s not a cure but it’s a start.”

And it bodes well for the industry down the road. MT&D

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technology tips Generic Maintenance Standards:

Do they Work?

A course attendee once told me “a mold was a mold”, in that they all do the same thing: “You squirt hot plastic in the back and a part comes out the front, so they all should need the same basic care.” Well, okay, that might be a high level view of what’s happening, but it’s not detailed enough to be useful in determining an accurate maintenance plan or PM work instructions.

What the attendee wanted — and what many seem to want — was a generic checklist that could be used for all of his molds. By the end of our maintenance course, he had a better understanding of what features of a mold and its environment will influence PM work instructions, but he still wanted to pare it down to something simpler since in his shop they had nothing to follow.

To put this request in perspective, it’s like all car owners needing a list of things to do to keep their cars running and performing perfectly all the time. Well, what if the car sits for extended amounts of time or is run hard for short bursts? Maybe the car is driven from coast-to-

By Steve Johnson, ToolingDocs LLC coast on a weekly basis. Does it sit out in the rain or is it garaged? Is the driver prone to riding the brakes or to accelerating hard? Are the roads rough or smooth? Dry Arizona air or salty LA humidity?

All of these issues require more “drive-time information” on what needs to be checked on a car after a known number of miles have been driven in specific conditions.

So the following list of typical automotive PM items needs to be completed sometime, but when to do it and exactly how to do it needs more instruction to be costefficient and performance-effective: •C heck/change the fluids (oil, transmission, etc.)

•C heck/adjust tire pressure •C heck/adjust brakes •C heck/replace wipers •C heck/replace lights •C heck/clean/replace filters Any of the above generic directives would cover all the different makes and models, but are so basic that car owners would waste time and money by either overor under-maintaining their vehicles, because they still

Table 1

Mold Start Data

Production Issues or defects

mold stop/pull data

q Press number

q Name of the defect

q Stop date and time

q Start date and time

q Type of defect (mold, part, electrical, etc.)

q Cycles, days, hours or parts run

q Cavity number or mold base position

q Who stopped it

q Date defect observed or blocked-off

q Stop reason

q Who started it qM old configuration or part number

q Who observed or blocked the defect

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©Alexander Bedrin/Getty Images/Thinkstock

Mold Performance Data Collected at the Press

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technology tips Table 2

mold repair data q In or out of press q Defects targeted qC orrective actions performed (replace, clean, rework, etc.) qW ho performed them (breakdown) q Tooling replaced q Labor hours required qM old status and stage (green-tag, blue, red, location, etc.) would not get the performance and reliability they need — when they need it.

And it’s the same with a mold. Considering all the process parameters, resins, presses, operators, environment, and other factors that can contribute to mold wear and breakage, having generic maintenance standards will only serve as a baseline or starting point for more detailed (mold-specific) and accurate standards.

For instance, the directives below should be performed on every mold at some frequency (cycle count) based on historical condition evaluations and mold performance.

• Clean and grease pins and bushings • Clean all vents and vent dumps • Clean plates of corrosion, rust, and off-gasses • Clean and grease interlocks • Clean water and air lines • Remove and inspect frame and cavity tooling for wear and damage • Replace all seals It’s not cost-effective to do all of these every time a mold is stopped or pulled from the press. Why not? Because doing so could be a huge waste of time ,and create opportunities for mistakes or excess wear through disassembly, cleaning, and reassembly of close-tolerance tooling.

All of the above PM directives work at some point with all molds, but a lot more instruction and supporting data needs to be gathered during the production run that will help dictate what really needs to be done in order to be truly cost-effective.

So how can you create valuable work instructions and

more accurate maintenance plans? By answering 13 questions about any mold being run (see Table 1).

Also needed are seven pieces of mold repair data to take into consideration when developing PM work instructions (see Table 2).

These, together with the performance data collected at the press, will serve as specific issues the mold suffers and typical resolutions after a certain amount of cycles are run. Using ongoing historical evaluations of these 20 pieces of data to form our PM work instructions will assure us of maximizing our time with the mold during bench work and PM. MT&D

Steve Johnson is the operations manager for ToolingDocs LLC, part of the Ohio-based PCIC Group of Companies.

Contact ToolingDocs at 419-281-0790 or email info@toolingdocs.com for more information.

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company profile Photo Credit: Dax Melmer/ The Windsor Star

A new era begins for an Oldcastle tool shop

By Mark Stephen, editor What with all the bumps in Canadian-American economic relations lately — did someone say Keystone XL pipeline? — it’s nice to be reminded that both sides can, in fact, make mutually beneficial arrangements.

Take Oldcastle, Ont.-based Cutting-Edge Technologies Ltd., for example. The tool and mold shop is undergoing a US$10 million-plus expansion, with plans to double its capacity and workforce over the next 18 months, thanks to a new partnership with a Michigan firm. Proper Group International, a Warren, Mich.-based injection mold maker, has acquired a majority ownership interest in Cutting-Edge — and both companies see it as a big step forward.

Founded by Sean O’Neil in April 2001, Cutting-Edge specializes in high-precision machining services for the tool, mold and die sector. The investment will allow the company to not only better serve current customers with even higher precision, value-added machining, but also branch out into the design and building of molds. “Proper Group was a customer of ours, and is one of the largest mold builders in the U.S.,” O’Neil said. “We’re going to start building molds for them and supporting their tooling business in Canada, and plan to branch out into our own customer base as well.”

CHANGE AND CONTINUITY Despite its long history with Proper Group, the move is a relatively unexpected one for Cutting-Edge. “We had always been strictly a subcontract shop, offering special-

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Sean O’Neil, president of CuttingEdge Technologies Ltd., on the shop floor. The company is undergoing a US$10 million expansion and hiring spree due to a partnership with American-based injection moldmaker Proper Group International.

ized services, and were not really looking to get into mold building,” O’Neil said. “But my long-time partner wanted to retire, and I was looking for a partner to move the business forward. I was approached by Proper Group, which was looking for a foothold in Canada.” The new ownership structure leaves O’Neil firmly in charge, and with the existing Cutting-Edge management team in place.

“Part of the $10 million investment includes expanding our manufacturing area and our engineering and design spaces, adding new equipment, and employee training and recruitment,” O’Neil said. “Our workforce of 35 could more than double if the company can recruit skilled trades workers. We’re looking for talent in every aspect of mold building, from designers to engineers to machinists. Our biggest challenge would definitely be manpower, which is not a new problem in this industry. Our growth will depend on finding the right talent.”

That challenge aside, O’Neil is enthused by the prospect of what could rightly be called Cutting-Edge 2.0.

“This is an exciting opportunity for our company, especially the employees on the shop floor — it will open up internal advancements that weren’t available to our staff before,” he said. “It will also open up new opportunities for our customers because, once we get into our new equipment acquisitions, we’ll be able to offer them services that we couldn’t before.”

Anyone else think we should maybe put CuttingEdge and Proper Group in charge of the Keystone negotiations?

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moldmaking / shop floor New square shoulder mill offering Seco Tools recently added a new helical tool to its Square T4-08 line of square shoulder mills that feature four cutting edges and an innovative tangential cutter design. Ideal for slotting and contouring/ shouldering applications, the Helical T4-08 excels in machining challenging materials such as cast iron, steel, stainless steel, and alloys.

Like other products within the line, the Helical T408’s strong, reliable pocket seats combined with multi-edge inserts optimize cutting stability and allow for clean 90° walls. The inserts mount tangentially in the cutter so that the cutting forces impact the thickest parts of the inserts, allowing manufacturers to achieve the required levels of strength for increased depths of cut with small diameters.

In addition to its high metal removal rates, users will also benefit from the Helical T4-08’s versatility, with options that include normal and close pitch variations, M08 and MD08 insert geometries, and MP3000, MK2050, and F40M grades. Various mounting types include Seco-Capto, Weldon, Arbor, and Combimaster.

The tool has cutting diameters that range from 25 mm to 54 mm and depths of cut between 22 mm and 64 mm.

Corner radii ranges from 0.4 mm to 1.6 mm. Furthermore, the entire Helical T4-08 range has integrated throughcoolant channels to provide extended tool life.

Seco Tools North America (Troy, Mich.); www.secotools.com; 248-528-5200

New thick turret insert slitting die Mate Precision Tooling introduces the new Versadie thick turret insert slitting die for D and E stations. The Versadie design takes clamp clearing operations to a new level by reducing material cost and waste for slitting operations by punching closely to the clamps; and allowing users to replace die inserts without replacing the entire slitting die.

Further enhancing productivity, Mate’s new Versadie features easily replaceable die inserts that accommodate lengths up to 4.560 inches

(115.82 mm) for E stations and 3.560 inches (90.42 mm) for D stations. These are currently the longest available in the industry.

Versadie is stronger than ordinary slitting tool dies, and withstands the most demanding punching operations. The die insert is precision manufactured from MPM82 tool steel. This high-speed, particle metallurgy steel allows for sharper edges on the die opening, giving Versadie high value and long-lasting versatility, which is ideal for slitting operations. Versadie also has tighter tolerances of the insert to the holder. These design features ensure greater machine uptime and lower tooling and fabricating costs. The die body itself is made of S7 shock-resistant tool steel.

The die body is easily shimmed after the insert is sharpened during routine maintenance. There is no need for special insert shims. Another important feature is Mate SlugFree die design, which prevents slug pulling and prevents damage to the piece part and the tooling.

Versadie is available in metric and inch sizes in standard rectangle, oval, and double D shapes. Special order designs are available for rectangle/oval, double rectangle, rectangle with tabs, trapezoid, cable opening, cable opening with tabs, and breakaway. Shims are available in D station.

Mate Precision Tooling (Anoka, Minn.); www.mate.com; 763-421-0230

Tough, shock-resistant drill bit carrying cases Walter Surface Technologies, a global industry leader in surface treatment technologies, has released its new Walter drill bit carrying case.

Made of shock-resistant, extra-thick polyethylene plastic materials, the bright orange-colored carrying case is designed to help protect Walter drill bits products from water, rust, oil, grease, and other contaminants.

Walter’s all-purpose drill bits offer heavy-duty, fully ground body construction; special bronze SST heat and surface treatment; a state-of-the-art, self-centering split point; and high flow spiral design for the fastest removal rate.

Available for high-performance HSIS Walter drill bit products such as the SST 118 quick shank and the SST+ 135 quick shank, the Walter drill bit carrying case offers a closed, quick-release belt clip, giving end-users a practical way to realistically work with a 29-piece drill bit set.

Walter Surface Technologies (Mississauga, Ont.); www.walter.com; 905-795-8555

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moldmaking / shop floor Non-toxic wrap protects metal from rust and corrosion Available from DMS Canada Ltd., MetalRustGuard is a non-toxic, VOC-free protective wrap that prevents rust and corrosion on any type of metal without harm to the user applying it or the environment it’s placed in.

MetalRustGuard is self-adhesive, and only requires a dry surface to be used in its application. Light pressure of the material to the metal prevents rust and corrosion without any other equipment needed. MetalRustGuard is ideal for shipping or storing metal for an extended period of time without worry of rust and corrosion.

MetalRustGuard’s base material is a hydrophobic polypropylene. The adhesiveness of the material is a proprietary wax formula that provides adhesion to the metal and prevents harmful contaminants in the atmosphere from corroding the metal on the inside.

MetalRustGuard’s ingredients create an impenetrable barrier to various weather and climate conditions including humidity, extreme cold, and marine environments from affecting its performance. Polypropylene’s chemical properties do not absorb water, but act like a water-retardant, pushing water away. The wax acts as a superior inhibitor against harmful atmospheric elements that cause corrosion.

MetalRustGuard comes in roll form, in widths of 4.5 inches, 6 inches, 9 inches, 12 inches, 18 inches, 36 inches, and 55 inches.

For a nominal fee, the material can be perforated to tear away at a desired length for quicker application, maximizing coverage and minimizing waste. Customizable and practically priced printing services of company logos on the material are also available, which provide excellent branding and a professional packaging touch.

DMS Canada Ltd. (Oldcastle, Ont.); www.dmscomponents.com; 800-265-4885

Advertiser’s Index Advertiser

Page

Website

AceTRONIC.........................MT&D 9........... www.acetronic.com Bohler-Uddeholm Ltd..........MT&D 2........... www.bucanada.com Sorel Forge........................MT&D 11......... www.sorelforge.com CAMM/APMA......................MT&D 15......... www.camm.ca; www.apma.ca Schmolz & Bickenbach.......MT&D 16......... www.schmolz-bickenbach.ca

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Custom engineered workholding system improves machining throughput

New machining projects and ones requiring improved throughput can benefit from a custom engineered workholding system from Kurt Manufacturing. The benefits include high-precision and repeatable part clamping; high-density, flexible clamping of a family of parts on the same fixture; high rigidity; and automated high productivity/output.

By maximizing the productive capacity of today’s machining centres, a Kurt Custom engineered workholding system will increase part output while lowering costs, which is accomplished with high-density workholding designs and fast load/unload features.

By first analyzing the possible use of its standard vise products, Kurt ensures the overall lowest workholding cost. By using standard products in conjunction with custom modifications, up-front costs and future maintenance can be greatly reduced. Kurt controls the manufacturing of both the standard product and custom fixture, ensuring the new workholding set-up is matched dimensionally.

Kurt’s custom workholding engineers have built an industry-leading reputation assisting automotive, aerospace, and other metalworking intensive industries to improve quality and reduce cycle times, and the custom engineered workholding includes options for hydraulics, air sensing, prox switches, and part gauging to accommodate various part sizes within a family of parts.

By integrating robot arms into fixtures, productivity can be greatly increased, allowing automated part loading, machining on all sides of parts, and unloading and stacking of finished machined parts. Systems also can include automated part gauging for quality, and real-time process control with complete part traceability. These custom systems can be designed for a single machining centre or to automate an entire cell of dozens of machining centres and support systems.

Kurt Manufacturing Company (Minneapolis, Minn.); www.kurtworkholding.com; 877-226-7823

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CAMM & APMA WORKING TOGETHER TO STRENGTHEN OUR INDUSTRY’S FUTURE

     

Two memberships in one More supplier days More B2B meetings More Trade shows More networking opportunities More webinar opportunities

CONTACT: Diane Deslippe, Executive Director, Canadian Association of Moldmakers 2000 Talbot Road West, Windsor, Ontario N9A 6S4 Cell: 519.919.0432 | diane@camm.ca | www.camm.ca

As a CAMM member, check and participate on events on the APMA website: www.apma.ca

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SCHMOLZ + BICKENBACH broke the mold when they introduced products like Formadur PHX Superclean, not to mention their entire line of Plastic Mold Materials. With over 160 years of steel production backing their brands, SCHMOLZ + BICKENBACH is not only a pioneer, but also a market leader in specialty steels. Their comprehensive range of products allows you to choose the ideally suited mold material for your application. In addition, an extensive range of value added services provides you with more alternatives from one source, SCHMOLZ + BICKENBACH.

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