NASA Insulation Technology

CO2 & Cost Reductions

We are world leaders in Continuous Improvement with Suppliers

Introductions & Relationship

Charlie Rupert – CEO of STS (Singh Thermal Systems)

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Technical Lead

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COLLABORATIVE

SUPPLY CHAINS

Edward Pretzel – CEO of CSC (Collaborative Supply Chains)

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Commercial Lead

CEO – Collaborative Supply Chains & Costing Expert (Metro Detroit)

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Cost Management Expert – Supply Chain Cost Modeling, Lean MFG, VAVE (30 years)

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BS Engineering - Manufacturing, Industrial & Operations

(University of Michigan, Ann Arbor)

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Manager Purchasing Cost Engineering – GM / Toyota

Global Cost Engineering Manager - Lear

Senior Global Cost Engineering Manager – ZF / TRW

Global Director Cost Engineering – Dana

Vice Pres. Cost Engineering. - APD (Advanced Purchasing Dynamics)

CEO – Collaborative Supply Chains & Costing-Expert

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3000 factories cost modeled, 250,000 parts analyzed & optimized

(US, Mexico, China, Korea, Thailand, Taiwan, Malaysia, W-EU, E-EU, Brazil, Canada, India)

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Speaker

Edward Pretzel – CEO

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Introductions & Relationship

Charlie Rupert – CEO of STS (Singh Thermal Systems)

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Charlie has 20 years of professional experience from Design, Industrial Engineering, Project Management, Purchasing and Supply Chain to deep university relationships in both engineering and business curriculums.

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Prior to SVS, Charlie held leadership positions in operations, purchasing and supply chain roles in prominent auto tier 1’s as well as oversight of capital equipment in solar, semi and chemical industries approaching a billion dollars annually. Operational positions included (auto tier 1); industrial engineering, lean six sigma, plant and operations management as well as a German expat assignment. Key automotive lighting experience was gained at Magneti Marelli with responsibility for purchasing and supplier quality for the NAFTA region.

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Charlie holds patents granted or pending a number of segments from manufacturing processes to product patents around light weighting technologies.

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Charlie, has a Bachelors Degree in Engineering Management with an ISM minor from Western Michigan University (#2 & #5 programs ranked nationally) and a Master in Business from the University of Michigan.

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COLLABORATIVE

SUPPLY CHAINS

Edward Pretzel – CEO of CSC (Collaborative Supply Chains)

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BIO is on the Next Page

Quick Business Case

TECHNOLOGY

• Mold Insulation = NASA grade technology
• Reduction of hot & cold spots
• Reduces operating temperatures & cycle times

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FINANCIAL & ENVIRONMENT IMPACT

• Cycle Time 15% Reduction = 5 - 8% savings to Sell Price
• CO2 15% Reduction = 50k lbs. / yr. per part

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SELF FUNDING (solution to budget issues and to go FAST)

• Self funding process to support the technology installation.
• There are no costs, no risks to suppliers or customers.
• CSC/STS bares all costs, design, build, install, test, launch, support of the insulation tech.

COLLABORATIVE

SUPPLY CHAINS

APPLICATION TO CURRENT PARTS

• Applicable to All Current Production Injection Molded Parts
• NO CHANGES to EXISTING TOOLING
• NO PPAP REQUIRED

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Traditional Hot Runner Systems:

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• Depending on design and allowed air gap, temperature variation can range from 10% to 30%

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• Hot runner temperature settings must be set to adjust for the coldest sections = HOT TEMPERATURES

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• Temperature settings are set in the UPPER LIMITS of the recommended processing range for the resin

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• The more heat required to move the resin means the more heat required to remove during cooling, causing a longer cycle time

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Temperature Variation of Hot Runners

Hot Runner Thermal Analysis

Temperature Variance

Thermal Mapping

• Blue areas in direct contact with the mold base

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• Green areas are the coldest sections which drives the temperature setting to hotter

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• Yellow areas are now ‘hot’ areas

COLLABORATIVE

SUPPLY CHAINS

Minimize Thermal Variation:

Hot Runner Thermal Analysis

Temperature Variance

Cycle Time Advantages & Lower Energy Requirement

• Yes, energy is saved in the hot runner by not running so ‘hot’.

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• We lower the operating temperature by about 15 – 20%.

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• After injection, the mold cools the part until solid

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• This cooling is roughly 40% from melt temp

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• The cooler the polymer is when injected, the less heat is required to remove = FASTER CYCLE TIME & START UP.

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• The temperature of the ejected part is still the same.

Example – Poly Pro part with mold cool time of 20 seconds

250° to 125°:

125°Δ in 20 seconds for Current Process

200° to 125°:

75°Δ in 12 seconds for Insulated HR

COLLABORATIVE

SUPPLY CHAINS

Example – Cycle Time Reduction

Packaging Mold – Caps:

• 8 cavity cap mold runs in 250 ton press

• Material: Exxon LDPE

• Husky Hot Runner System

• Hot runner temp 425 F with barrel temps at 450 F

With Insulation:

• Insulation applied to main hot runner as a retrofit.

• Set temps at original target of 375 F manifold, 390 F barrel temps

• Able to increase cooling speed without sacrificing quality

COLLABORATIVE

SUPPLY CHAINS

Before

Example – Mold Installation (workshop at the supplier)

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SUPPLY CHAINS

Design, Build and Prep:

3-4 week turn around from approval to ready to install.

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Installation, Test Runs:

Installation is 1 day and 1 day for testing and confirmation.

After

Initial Hot Runner Temps:

• Temps running 50F hotter than melt temp
• Processing steps lowered:
• 430 to 380
• Barrel temps running 430+
• Reduced temps by 30F

Lyondell Basell Process Recommendations

450

Melt

Current

Final

Degrees F

380

380

+70

-15.6%

Press Final Temps

Example – Temperature Reduction

COLLABORATIVE

SUPPLY CHAINS

Process Changes:

• Main parameter targeted: Pack & Hold
• Slowed Injection and Screw Recovery
• Newer Hydraulic Press, in good condition
• Total Cool time of 25 reduced to 18

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• Cycle Time Result: 44 Seconds to 39 Seconds – Machine Limited

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• Estimated Savings per Year: $284,000
• 5 seconds = .00138 std hr.
• $200/hr = labor and burden rate
• Savings / Pc. = $200 x .001388 = $.29/pc
• 100,000 pcs / yr.

Royal Actual Process

Current

New

Cure

Pack

25.00

18.00

-28.0%

Cycle Time Summary in Seconds

Supplier

1

Inj�Screw

Pack�Hold

New

44

39

-11%

Total Cooling

New Establish Process

Original Process Received from Supplier

Lowered injection pressure 2.5% by slowing injection speed and screw recovery

Example – Cycle Time Reduction

COLLABORATIVE

SUPPLY CHAINS

CO2 Reduction Example

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Energy consumption per part is a function of yield

• Faster time-to-temp on startup means less wasted energy warming up
• Faster cycle time means more parts per hour, means less energy per part
• Less energy per part means less CO2 = 15% average per part
• Source of energy matters in amount of CO2 (Coal vs Natural Gas)

Cell Phone Case – On Shoring & CO2

COLLABORATIVE

SUPPLY CHAINS

CO2 Reduction Example

Calculation Assumptions:

• 1100 Ton Hydraulic Press: 4 yrs.
• Avg KW 250
• Regional Power Generation: Natural Gas
• CO2 Emissions from Natural Gas: 0.91 pounds / KWH
• Press Emissions lbs. per hour CO2: 227.5

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Program Details:

• Cycle Time Original: 44 Seconds
• Cycle Time STS: 39 Seconds

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Parts Per Hour (2 Cavity Mold):

• Original Cycle Time Parts / Hour: 164
• STS Cycle Time Parts / Hour: 187

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Annual Production Volume:

• Program Unit Volume: 620,540
• CO2 Original 862,723 lbs. CO2
• CO2 STS 754,883 lbs. CO2
• CO2 Saved 323,521 lbs. CO2 (Jeep Grand Cherokee)

COLLABORATIVE

SUPPLY CHAINS

Process of Evaluation, Prep & Install

Step 1 – Identify Part, Cost Breakdown, Confirm Potential Savings

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Step 2 – Gather Tooling CAD & current process parameters

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Step 3 – Confirm strong probability for success, approval to move forward

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Step 4 – Design, Build and Prep the insulation, identify workshop date

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Step 5 – Execute workshop (1 - 2 days), confirm success

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Step 6 – Update Lower Costs and implementation Date

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COLLABORATIVE

SUPPLY CHAINS

Process of Evaluation, Prep & Install

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SUPPLY CHAINS

Guarantee

• No Up-Front Cost to Customer

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• No Up-Front Cost to Supplier

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• If it does not work, then the insulation can simply be removed

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• Guaranteed 5 years from install date from manufactures defects

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• We provide the banding and banding tools to support removal and reinstallation of the insulation as required.

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COLLABORATIVE

SUPPLY CHAINS

PPAP Not Required

• PPAP – Production Part Approval Process

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• There is no change to the tooling.

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• There is no change to the thermal profile of the ejected part.

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• Still within the temperature parameter range.

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• Customers and suppliers are not performing an additional PPAPs.

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COLLABORATIVE

SUPPLY CHAINS

Pilot Project Process

Customer (Purchasing)

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• Answer any questions

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• Work with management for approval

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• Complete NDA

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• Identify a cooperative supplier

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• Identify a potential part

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• Make introduction with supplier

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Supplier

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• Choose Supplier that has a more open mind

• Review Technology with Supplier

• Work with Supplier management for approval

• Identify a part

• Gather part and tooling data

• Schedule a date of installation and trial

(1-day at supplier)

• Confirm cycle time reduction of temperature

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COLLABORATIVE

SUPPLY CHAINS

Results, Customers

1. 5 years experience
2. # of installations = 100+ and growing
3. # of failures = 0

3. Industries

• Auto
• Consumer
• Packaging
• Heavy Truck
• Medical

4. Product Types = Lighting, under hood, structural, battery, seating, interior, exterior, door modules

5. Materials = PC, ABS, PA, PP, HDPE, TPO, TPE, TPU

6. Range of Tonnage and size of tools and parts

• 300-4,000
• 1k to 4k machines

7. Range of Cavities = 1-32

8. # of parts in the marketplace = 70,000,000

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COLLABORATIVE

SUPPLY CHAINS

Thank You

We are world leaders in Continuous Improvement in Supply Chains

Edward Pretzel

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734 834 3636

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Email – edpretzel@collaborativesupplychains.com

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Customers

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SUPPLY CHAINS