Innovation Triumph: Milacron India’s Strategic Solution for High-Tonnage Injection Molding Machines

Milacron India Pvt Ltd (MIPL), a frontrunner in manufacturing high-tonnage injection molding machines, encountered formidable challenges in its quest to deliver top-notch, cost-competitive products tailored to customer demands. To emerge as a market leader in original equipment manufacturing (OEM) for such machines, MIPL embarked on a strategic journey to meet customer expectations while maintaining quality and cost-effectiveness.

The realm of higher-tonnage injection molding machines presented both promise and competition for MIPL. To establish supremacy, the company needed to offer superior products at competitive prices without compromising on quality. This necessitated a strategic approach to overcome market challenges effectively.

To bridge the gap between MIPL and its customers, a comprehensive customer survey was initiated, focusing on higher-tonnage machines. Insights gleaned from this survey highlighted key areas for improvement within the clamp unit of MIPL’s plastic processing machines, providing a clear roadmap for enhancement.

Recognizing the imperative of adapting to evolving market dynamics, MIPL prioritized timely delivery and optimal performance. This entailed cost containment and gaining a competitive edge.

Solution Generation, Innovation, and Complexity:

Drawing from customer feedback, MIPL concentrated on enhancing the clamp unit to align with customer needs.

Material Selection: Rigorous evaluation of materials led to conceptual weight reductions, enhancing closing speed and reducing costs while preserving functionality. Design for Manufacturability (DFM): Optimizing the clamp unit design for efficient manufacturing processes minimized production costs. Value Engineering: Through value engineering analysis, cost savings were achieved by identifying alternative designs and manufacturing methods without compromising performance. Supplier Collaboration: Engaging with suppliers facilitated cost-reduction opportunities by leveraging their expertise. Design Failure Mode and Effects Analysis (DFMEA): Proactive identification and mitigation of potential failures ensured high product quality. Continuous Improvement: A systematic approach to ongoing cost optimization and improvement was established, ensuring sustained efficiency. The outcome surpassed MIPL’s expectations, achieving an impressive average reduction of 22% in the clamp unit’s weight without compromising performance.

Challenges Faced:

Achieving cost reduction while maintaining tonnage specifications and machine performance. Ensuring expertise in casting manufacturing and supplier competency. Establishing proficiency in plating processes on castings at the supplier’s end. Enhancing the quality performance of clamp castings. Developing suppliers for casting machining of large-sized components. Facilitating single-piece machine loading through existing crane facilities.

Original source MMI