Mold Making & Injection Molding - Bluestar Mould Group 2015
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Transcript of Mold Making & Injection Molding - Bluestar Mould Group 2015
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One-stop Total Plastic Solution Provider
One-stop Total Plastic Solution Provider
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One-stop Total Plastic Solution Provider
Business Scope
+ Product R&D
+ Prototype making
+ Insert molding
+ 2K molds
+ Reverse mold+ Over molding
+ Inset mold
+ Stack mold
+ Multi-cavity hot runner molds+ Mass production
+ Assembly
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History
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Organizational Chart
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Company Overview
Company Overview
> Locations
> Markets and Turnover> Employee
> Organization and Management
> Global Network
> Company Culture> Events Review
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Locations
A Main Factory 20,000 in Baoan,
Shenzhen
(45 minute drive from Shekou to Baoan)
B Corporate Headquarters, Technology
Building, Shekou, Shenzhen
C Hong Kong Airport
(40 minute ferry ride to Shekou)
A
B
C
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Markets and Turnover
510 employees, With Engineers in America and Mexico
Sales Revenue of 2015 is expected to reach approximately
$78,000,000USD
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Employee Statistics
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Organization and Management
Functional Dept.Fareast MoldingBluestar MouldAuto PartsTool Manufacture
Henley Li
Director of HR
&Finance
Brown Huang
Director of
Admin
Chen Yonghe
Manager
George YangDFM Manager
Peter Luo
VP
Tony Wang
Manager
Kenny Wei
Sales Manager
Lloyd DeShane
Sales DirectorAngela Wang
Sales Director
Guide Xu
Technical
Director
Philip Huang
BSM President
Kevin Yang
Director
Adah Cao
VP
Neil Heppel
Project Manager
Mandy Qiao
Manager
John
US Technical
SupportFord
Ge Gong
Chief Engineer
GeorgeConsultant
(Ford
Kamel
Management
Advisor
You Jing
Tooling
Advisor
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Global Network
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Company Culture
Mission: To create value for customers
To bring benefits for employeesTo share the social responsibility
Team Culture:
Safety first
Never give up
Practical and hands-onBe innovative
Philosophy: Sincerity, Self-discipline, Vision and Responsibility
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Exhibitions
C biliti
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Capabilities
Capabilities
> Research and Development
> Engineering and Analysis
> Project Management Procedures
>Tooling>Tool Trial Plant
> Tool trial/trial-production flow chart
> Molding
> Quality
> Testing Equipment
> Component Suppliers
> Capital Investments
> Investment Plan
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Research and Development
Laboratory19 R&D staff mainly engaged in auto components, body
parts, internal and external products research, design and
development.
Cooperate with Guangdong Mold Association and
Automobile Research Institute in South China University of
Technology.
Test laboratoryabrasion resistance,
moisture resistance,
cold resistance,
wet & heat cycle,
hardy impact,
light aging resistance,
high temperature aging resistance,materials tensile,
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Engineering and Analysis
Technical Dept. has 8 senior engineers, who are specialized to do DFM and
Moldflow.
TechnicalDept.
Design Dept. has 40 design engineers, they use Pro Engineer, UG,
SolidWork, AutoCAD and Master cam UG to design and program.DesignDept.
Tooling Dept. has about 260 professional mold makers. We can produce700~800 sets of molds per year, from 150mmX150mm to 2.5mX3.5M, up
to 40T.
ToolingDept.
We do trial-production and keep the mould running well in the machine
for around 6 hours.Mold Trial
Team
Mold Checking Team has 10 Mold checking engineers. They check the
manufacturing process and inspect the molds.Mold
CheckingTeam
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Project Management Procedures
MoldDesign
Customer
Project
Team
Sales
Technical Dept.
Design Dept.
Tooling Dept.
Outsource
Purchasing
Dept.
Mold Trial Team
Commercial
Communication
DFM
Outsource processing
Standard Parts
Mold Base
Raw Material
Mold Trial
Mold Checking
Team
Mold
Building
Checking
Process
Tool
Inspection
Project Team is the core part
of entire project management
system. It will lead and
coordinate on each process
One project team can follow up
50~60 molds each time.
For more projects, we can set up
a second team.
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One-stop Total Plastic Solution Provider
Tool Making Capacity
CNC - 20 Machines
Maximum machining capability 3.2 x 1.9m
Mori Seiki CNC machine, 1500 x 600m, tolerance
0.003mm Mikron CNC machine, 710 x 400mm, tolerance0.005mm
Fanuc CNC machine, 500 x 400 x 200mm, tolerance0.005mm
DMG 5Axes CNC Machine
EDM 15 Machines
Sodick mirror EDM machine, tolerance0.002mm
Other EDM machinesWire-cut 9 Machines
Makino Wire-cut machine , tolerance0.005mm
Charmilles Wire-cut machine , tolerance0.005mm
Sodick Wire-cut machine, tolerance0.002mm
Tolerance0.002mm
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One-stop Total Plastic Solution Provider
Tool Making Capacity
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New Tool & Trial Plant
1600T- 1set 850T - 1set
560T - 1set
450T - 1set
360t - 1set
350T - 2sets
250T - 2sets
168T - 1set
1000M2 trial plant: 10 tool trial injection machines with robot from 168T to
1600T
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New Tool & Trial Plant
3000M2 tool assembly area with big fitting machine and CNC machine, increase
40% tool making capacity
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Injection Molding Capabilities
43 injection machines with robot from 50T to 2000T
Toshiba high speed injection machines from 100T to 350T
Vertical injection molding machines
Haitian injection machines
Haitian SA530 Bi-injection
High volume production
ABS, PC, PC + ABS, POM, PMMA, PA, PPT, PE, PVC and other common
materials and engineering plastics
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One-stop Total Plastic Solution Provider
Quality Systems
Certifications
ISO9001:2008 since 2006
ISO14001:2004 since 2008
TS16949:2009 since 2010
BSM have the systems in placeensure traceability down to everyprocess on a single part, componentand material; from design to delivery.
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Testing Equipment
CMM-03 CMM-02 CMM-01
24
Hardness Guage Height Guage 2CMM
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Component Suppliers
Steel
Hot
runner
Texture
Mold base
Resin
Hydro-
cylinder
Standard
parts
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2015 Equipment Investments
$1,920,000USD investment fund was scheduled for 2015
New Investment Fund in 2015
NO. Equipment List Brand Model Work Spec Quantity DateCountryOrigin
Supplier Condition Price
1 Milling Machine GuiBei GM150 4501500200mm 1 2015.3 GuangXi On going US$5,000
2 Milling Machine GuiBei GM150 4501500200mm 1 2015.3 GuangXi On going US$5,000
3 Wire-cut Founder DK7740 400500400mm 1 2015.8 JiangSu Planning US$13,000
4 Wire-cut Founder DK7750 500630600mm 1 2015.8 JiangSu Planning US$17,000
5 CNC Machine OKUMA MB-56VA 1000*560*400 1 2015.3 Japan OKUMA On going US$200,000
6 CNC Machine OKUMA MB-56VA 1000*560*400 1 2015.3 Japan OKUMA On going US$200,000
7 CNC Machine DMGHSC-
75LINEAR750*600*560 1 2015.5 Germany DMG Arrived US$500,000
8 Graphite Machine SMD SMD-860 700*780*330 1 2015.9 Shenzhen SMD Planning US$500,000
95Axes CNC
MachineDMG 80EVO 800-700 1 2015.5 Germany DMG Arrived US$480,000
Total US$1,920,000
I Pl
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Investment Plan
Investment plan BSM Industrial ParkFocus on automotive parts design and manufacturing.
2014 K j t
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2014 Key Projects
2014 Key projects
3
FORD PI
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FORD-PI
In 2014, BSM set up an exclusive team on Ford-PI project and with exclusively designated
skilled workers, machines and equipment for volume production while at the same time
sticking to a very strict quality control policy.
BSM joint-handedly developed the Interior Atmosphere Lamp with PI and had a verysmooth mass production of the lamp.
ERP I t A t P t M ki
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ERP Into Auto Parts Making
The year of 2014 witnessed a successful launch of the ERP system into BSM Auto Parts
Dept. With this system, production planning, material procurement, warehouse
management, shipment & delivery was able to smoothly carry through.
ERP I t M ld M ki
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ERP Into Mould Making
In the same year, B9 ERP System was also applied to BSM Mould Making Dept.
for mould design, material procurement, production scheduling, process
checking and mold manufacturing. The launch was proved to be very successful
with positive comments from clients.
M ld D i C t
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Mould Design Center
BSM set up a mould design Center to offer customers and clients services on molding
analysis, mould structuring solutions, mould flow analysis, mould secondary
development and standards archiving.
Standard Upgrade
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Standard Upgrade
BSM upgraded mould design standards in 2014 while at the same time had a restudy
on clients standards and expectations to make sure its design and manufacturing is
100% in compliance with clients requirements.
Auto Parts R&D Dept & Labs
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Auto Parts R&D Dept. & Labs
BSM set up Auto Parts R&D Dept (with laboratory attached) with Guangdong Mould
Association and Automotive Research Institute, South China Technology University to
design, R&D and test on car parts (interior & exterior and component structures). The
CAPSA, Thyssenkrup and PI were also developed and tested in the lab. Additionally, withthe participation of the GAC design team, the R&D capability was further upgraded.
CASPA Fender
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CASPA Fender
Front Fender L Front Fender R Rear Fender L Rear Fender R
Nov, 2013 -Aug, 2014 BSM completed the design of CAPSA B751 Fenders, all together 4
products-front fender(left and right), and rear fenders (left and right).
Sept-Dec ,2014, moulds were completed.
29th, Sept- 9th, Dec, 2014, testing devices were designed and manufactured and PASS
report was issued.
CASPA Project
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CASPA Project
Item BSM project no.Part
PictureCavity Material Color Part Size T1 Time
1 97K12.3 BSM14289 1X2 PA6 BLACK 10*19*T0.8 2015-1-14
2 97K12.14-1 BSM14222 1X2 PP BLACK 1000*360*560 2014-12-5
3 97K12.14-2 BSM14221 1X2 PP BLACK 850*480*610 2014-12-5
Fan project of DENSO Engine System
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Fan project of DENSO Engine System
In 2014, BSM successfully launched the R&D of Denso/2BW engine fans.
VW Intake Pipe for Euro Delphi
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VW Intake Pipe for Euro Delphi
Moulds for VW Intake pipe (Delphi Euro) was successfully developed with 60 moulds
and 110 products. The moulds were on-time delivered to client factories (Poland and
Shenyang ) .
Project Delphi Euro Total: 60 tooling sets
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Project Delphi Euro----Total: 60 tooling sets
ItemBSM Mold
No.Part
PicturePart Name Cavity
Steel&Hardness
SurfaceRequest
Color T1 Plan Updates
1 88K11.46-1
16476661-PAR02_001_MLB_VALVE_AI_
OSA_LHD_140115
2+2(2K)
A&B
:P20CO&CA:2343
(48~52HRC)
CA:600#CO:320#
black 2015.1.5 Mold was
transferred
2 88K11.46-2
16476662-PAR02_001_MLB_VALVE_AIR
_RECIRCULATION_LHD_140115
2+2(2K)
A&B
:P20CO&CA:2343(48~52HRC)
CA:600#CO:320#
black 2015.1.5 Mold was
transferred
3 88K11.46-5
16476627-PAR02_001_MLB_T1_VALVE_TEMP_COLD_3RD_CUSTOME
R_LEVEL_140115
2+2(2K)
A&B
:P20CO&CA:2343(48~52HRC)
CA:600#CO:320#
black 2015.1.5 Mold was
transferred
4 88K11.46-6
6476628-PAR02_001_MLB_T1_VALVE_
TEMP_HOT_1401152+2(2K)
A&B
:P20CO&CA:2343(48~52HRC)
CA:600#CO:320#
black 2015.1.5 Mold wastransferred
5 88K11.46-7
16476643-PAR02_001_MLB_OUTLET_FO
OT_REAR_1401152+2(2K)
A&B
:P20CO&CA:2343(48~52HRC)
CA:600#CO:320#
black 2015.1.5 Mold was
transferred
6 88K11.46-8
16476644-PAR02_001_MLB_VALVE_VEN
T_REAR_1401152+2(2K)
A&B
:P20CO&CA:2343(48~52HRC)
CA:600#CO:320#
black 2015.1.5 Mold was
transferred
7 88K11.46-9
16476645-PAR02_001_MLB_FOOT_FRONT_LHS_140115+16476647-
PAR02_001_MLB_FOOT_FRONT_RHS_140115
2+2+2+2(2K)
A&B
:P20CO&CA:2343(48~52HRC)
CA:600#CO:320#
black 2015.1.5 Mold was
transferred
8 88K11.46-
10
16476646-PAR02_001_MLB_VALVE_SID
E_VENT_1401152+2(2K)
A&B
:P20CO&CA:2343(48~52HRC)
CA:600#CO:320#
black 2015.1.5 Mold was
tansfered
A68 Side Skirt (Yanfeng Plastic Omnium
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A68 Side Skirt (Yanfeng Plastic Omnium
One-stop Total Plastic Solution Provider.
The R&D for A68 Side Skirt (Yanfeng Plastic Omnium) was successfully developed
in the same year. Product test result showed satisfactory and production has also
been put on 2000T injection machine.
A28 Bumper (GAC Trumpchi)
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A28 Bumper (GAC Trumpchi)
One-stop Total Plastic Solution Provider.
A28 Bumper mould of GAC Trumpchi was developed with client satisfaction. The
mould was delivered to Zhongxing Yanfeng factory and put on 2000T injection
machine.
Thyssenkrup
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Thyssenkrup
In 2014, more than 30 auto parts categories for Thyssenkrupp made by BSM
passed test and got customers approval, which are already put into production in
BSMs workshop. Among them, project of Ford AFSAudi B80V, Fiat Giorgio and SZL
Holder passed customers DA6.3 audit at the same time.
Ford/Roush
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Ford/Roush
One-stop Total Plastic Solution Provider.
30 Ford/Roush moulds were developed in 2014 with all together 60 parts categories,
all of which have been delivered to America for production.
Ford/Roush ----Total: 30 sets toolings
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Ford/Roush ----Total: 30 sets toolings
One-stop Total Plastic Solution Provider.
Item BSM Mold No.CustomerMold No.
Part Picture Cavity Material Color Part SizeT1 Lead
Time
1 BSM92K44.273-1 114857_01 2+2 Glass fill Nylon BLACK 122x100x46 2014-4-1
2 BSM 92K44.273-2 114857_02 2+2 Glass fill Nylon BLACK 122x100x46 2014-4-1
3 BSM 92K44.273-3 114857_03 1+1 Glass fill Nylon BLACK 330x130x99 2014-4-30
4 BSM 92K44.273-4 114857_04 1+1 Glass fill Nylon BLACK 280x126x110 2014-4-30
5 BSM 92K44.273-5 114857_05 2+2 Glass fill Nylon BLACK 120x120x65 2014-4-1
6 BSM 92K44.297-1 114800-01_A
Pillar Tweeter 1+1
Basell SG802N
PP BLACK 150x80x60 2014-2-20
7 BSM 92K44.297-2 114800-02_A
Pillar Defroster 1+1
Basell SG802N
PP BLACK 120x60x40 2014-3-22
8 BSM 92K44.297-8
114800-08 B
Upper RibCartridge
1+1 Basell SG802NPP Nature 360x250x66 2014-3-24
9 BSM 92K44.297-9 114800-09 B
Upper Slider 1X2
Basell SG802N
PP BLACK 200x48x5 2014-3-17
10 BSM92K44.322-01 115331-01 1+1 PP7855 NATURE 440x350x89 2014-7-18
Strategic Partnerships
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Strategic Partnerships
Strategic Partnerships4
Tier 1 and 2 suppliers to Toyota
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Tier 1 and 2 suppliers to Toyota
One-stop Total Plastic Solution Provider.
2 years of successful Partnerships with Tier 1
Toyota suppliers
Dedicated Project Management team
70 tools in 2012 and 2013
Current program 870A and 982A underwayCurrent Programs include;
BSM >> Ecoplas >> 466A
BSM >> Ecoplas >> 053A
BSM >> Ecoplas >> 883A
BSM >> Mecaplast >> 466ABSM >> Farplas >> 466A
BSM >> Roush >> 760A
Panel Sub Assy Instr
Cluster FinisherControl Armrest Hinge
Cup Holder
Control Pillar Lower Holder, Hood StayFront Seat Cushion
Inner Shield
Front Seat CushionInner ShieldGrip Assy
Instrument PanelUnder Cover RH
Garnish Sub Assy InstrCluster Finisher Lower
Front Door Armrest Insert
Grill
Seat Track Bracket
Inner Cover
Front Seat Cushion
Edge ProtectorConsole Box Insert
Cover Front Floor
ROUSH/FORD/CHRYSLER
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ROUSH/FORD/CHRYSLER
5 years of successful Partnership
Dedicated Roush Project Management team
90 tools in 2013, commitment for 120 tools in 2014
2013 Euromold Partner to show strong China partner
Full time dedicated Roush Engineer on staff with
dedicated office space in Corporate facility and factory
Daily transportation for engineers to & from the factory China cell phone and IT support
BSM Engineering support in America for quick design
approval and tooling trials.
Global Projects, Duplicate tooling design for China,
America and Europe
Current Programs include;
BSM >> Roush >> Toyota 760ABSM >> Roush >> (Interior trim) Ford
BSM >> Roush >> Chrysler
BSM >> Roush >> (exterior) Ford
BSM >> Roush >> Honda
BSM >> Roush >> Wilber
BSM >> Roush >> Summit Polymers
Partnership with PI
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Partnership with PI
One-stop Total Plastic Solution Provider.
5 years partnership for mold and molding
Dedicated Pacific Insight Project Management team
110 tools in 2013, commitment for 140 tools in 2014
Rapid prototyping tooling and production tooling
Molding
We produce all molded parts and ship to
Mexico for final assembly Transfer tooling from other Asian and Canadian
molders
We manage all logistics to Mexico and have a
warehouse inside of PI to manage materials
We have a dedicated BSM employee to manage
quality and the warehouse in Mexico
BSM Engineering support in America, full time BSMengineer on staff at Pacific Insight in Detroit, USA.
Current Programs include;
BSM >> Pacific Insight >> Ford
BSM >> Pacific Insight >> GM
BSM >> Pacific Insight >> Caterpillar
Lamp project for Trucklite/wipac - 1
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One-stop Total Plastic Solution Provider
Lamp project for Trucklite/wipac 1
One-stop Total Plastic Solution Provider.
Current Programs include
BSM >> Trucklite>> cascadia + Bugatti
BSM >> Trucklite>> Navistar
BSM >> Trucklite>> Volvo project
BSM >> Wipac >> Aston Martin One-77BSM >> Daimler
Front lens
Rear lamp reflector
Housing
Lens
Head lamp Housing Housing
Lens
Housing
Turnbody
Lamp project for Trucklite/wipac - 2
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One-stop Total Plastic Solution ProviderOne-stop Total Plastic Solution Provider.
Interior Lamps
Headlamps
Rear Lamps
Signal Lighting
Marker Lamps
Numberplate
Lamps/HoldersWarning LampsRectangular Front
Fog Lamp
Reflectors
Lamp project for Trucklite/wipac 2
Dedicated project management
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One-stop Total Plastic Solution Provider
Dedicated project management
One-stop Total Plastic Solution Provider.
CAC tank CAC Tank Inlet & Outlet
Central wheel
Central panel
Lateral L/R defrost
cover
Instrument panelSpeaker
Glove box
Radiator Outlet
Radiator Inlet
Middle Console for Skoda Rapid
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One-stop Total Plastic Solution Provider
Middle Console for Skoda Rapid
One-stop Total Plastic Solution Provider.
B Pillar
Wheel Cover
Bar
Middle Console Inner part
Middle Console Outer part
Middle Console AssemblyMiddle Console
Main Customers
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Safety Awareness
http://www.google.com.hk/url?q=http://www.tobalinaconsulting.com/&sa=U&ei=gIZQU77tGMiRiQe92oHwBA&ved=0CDMQ9QEwAw&usg=AFQjCNHeadh7HxRkgJ7Av0Yq6b7fkcJr5A -
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y
Safety Awareness
> House Keeping> Safety equipment for employees> Safety Education> Reduction in accidents
5
Housekeeping
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p g
Clear walkways and clean floors to eliminate falls and injury
Safety Equipment
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y q p
Example of Fire safety Training
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One-stop Total Plastic Solution Provider
p y g
Reduction in accidents
-
7/23/2019 Mold Making & Injection Molding - Bluestar Mould Group 2015
58/59
One-stop Total Plastic Solution Provider
Yearly Injury Summary
2011 2012 2013 2014
All Accidents 34 32 23 93 day Accidents 10 7 6 4
7 day Accidents 6 4 3 2
0
5
10
15
20
25
30
35
40
2011 2012 2013 2014
All Accidents
3 Day Accidents
7 day Accidents
-
7/23/2019 Mold Making & Injection Molding - Bluestar Mould Group 2015
59/59
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