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Posts Tagged ‘Process’

An introduction to Room Temperature Vacuum Casting

This process of molding is applied with the utilization of a vacuum chamber to extract the liquefied material into the mold. The method of vacuum casting is applicable when the mold that is desired has complex details or undercuts. It is also utilized when there is a concern of air entrapment or if the material has fibrous properties or wire reinforces.

A two piece silicone mold is placed in a vacuum chamber while the raw liquefied material is mixed and degassed; this is done when dissolved gasses are removed from liquid materials called degasification applied to prevent gas bubbles formation that is undesirable when a smooth finish is required. After the extraction of gasses is completed, the liquid material is then poured into the mold. The vacuum is then released and the mold is taken out of the vacuum chamber.

After this procedure, the vacuum casting is cured in an oven. Curing is a process of toughening or hardening of the liquefied material. This can also be applied to polyurethane and other plastics like acrylic. The silicone mold can be reused to up to 20 times maximum where it will start to deteriorate and can no longer be useful. 

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In the oven, it takes to up to hours for the liquid material to be cured depending on its size. After an exothermic reaction of the plastics, the cavity is opened and the molded plastic is removed. The silicone cavity is the closed and the procedure done again.

The disadvantage of Vacuum Casting is that it is expensive and is not preferred for mass production. However a substitute is available instead of this method known as Reaction Injection Molding. This process does not require expensive vacuum chambers and mixing facilities. The process utilizes simple plastic injection system with a couple of pressurized chambers.

So in Short

Vacuum casting is a prototyping technology used when you need a short run of your 3d cad model made out of a PolyUrethane with properties close to real injected plastics such as ABS, POM ,PA or TPE’s TPR rubbers

Usually series of 5-100 pieces will be run using this casting technology.

WHAT ARE THE ADVANTAGES OF Vacuum casting?

The main advantages of this process are amuch lower tooling costs and a quicker turn-around than traditional steel mould making. the lead-time to create casted models is around 7-10 days.

The products have an exceptional detail and accuracy which comes close to the final injected plastic parts.

Flexible silicone moulds allow significant undercuts, simplifying mould-making and containing costs.

The process:

The first step of vacuum casting process involves encapsulating/enclosing a master model in a liquid Silicone rubber. Than a vacuum is applied to the mould. The mould is then cured in an oven at around 70°C

Once cured the mould can be split up in 2 or more parts, at which point the master model is removed leaving a mould cavity perfectly replicating the master model.

what is possible with vacuum casting?;

We can make double or triple shot products, we can cast rubber or TPE or TPR like materials. (with 20-80 shore A hardness)

We can vacuum cast optical clear plastics ( same like PMMA) and we can use Inserts in the products.

Find More Polyurethane Casting Articles

In recent years, steady and rapid economic development, stimulating rapid growth in fixed assets investment, China Mould market demand. As the industry improve its competitiveness and national policy support, domestic rapid prototype Shenzhen mold industry output value and sales revenue for many years to maintain the growth rate of 20%. Die Network CEO, Shenzhen Institute of Deputy Secretary-General Luo Baihui mold technology recently introduced to the Dongguan Daily News the latest developments in the mold industry.

1, mold development prospects of the industry

1, mold market prospects in China

Mold applications continues to expand, the field has been applied to the mold that the larger and higher demand of industrial development to mold faster than the speed of development of other manufacturing industries has become a universal law, mold the world market demand, in recent years, the market total has been between 600 ~ 65 billion U.S. dollars, while China’s export was not mold to 8%, “during” can expand this share, and with the development trend of economic globalization has become more evident, mold manufacturing industry gradually China and the multinational corporations to transfer mold our country has become more evident towards the procurement of foreign and private capital to continue to favor China’s mold industry, China’s mold industry more opportunities than challenges, the future market prospects of international mold, China mold is still large room for development.

2, mold product market and increase their competitiveness

At present, China is facing the technological advantages of the developed countries and developing countries, the dual pressures of price advantage. Industrial countries die with its technological and business strengths, in the high-end molds a competitive advantage, as they are gradually entering the country, the mold industry in China becomes a tremendous challenge; India, Thailand and Eastern European countries in recent years, industrial mold developed very rapidly and the price of its mold also has a strong competitive advantage, China’s mold industry, the cost and price advantage will gradually weaken and eventually disappear. Luobai Hui said that China must die enterprises technology, management and personnel training efforts, and actively introducing foreign advanced mold manufacturing technology to enhance the ability of high-end product development die, adjusting product structure mold, mold products, continuously improve our international competitiveness.

3, mold growth rate of industry

China’s national economy in the “Eleventh Five-Year” period will continue to maintain relatively fast growth rate, to the mold industry, the development of a reliable macro support. Automotive, IT, electronic information, household appliances, OA office equipment, machinery and building materials industry, aerospace, mold needs are large power tools, home appliances and electronic information industries only example of a refrigerator Xu Yong mold about 150 parts , requiring a total of about 350 sets of molds; a need for automatic washing machine more than 150 sets of molds; one air conditioner, only to be 20 sets of plastic mold; die each model takes more than 30 sets of computers, along with its matching printer need to die more than 20 single deputy; also notebook computer, the network will have tens of millions of units set-top box market. As much as the current models developed abroad, mold import more, as China developed its own capabilities in this regard will be greatly increased demand for mold. China’s mold industry can be expected in a good macro environment of rapid development.

4, mold industry opportunities and challenges

On the one hand for the mold industry, domestic and international situation provides an unprecedented development in the development of space, while the other mold will also face more intense competitive challenges, in addition to international competition, at home, Xiaoshan, Shanghai and Shenzhen, will develop mold industries, such as Xiaoshan You into the mold company’s annual sales revenue reached 2 billion, as Friends of the Japanese professional mold factory mechanic’s wholly-owned enterprises, mainly engaged in automotive and appliance dies production, is currently being planned for the support of Xiaoshan City Hong Kong GEM; Huangyan mold industry in management, equipment, technology has also been taking the forefront in the province; mold more than 30 million annual production value of Wenzhou City, is preparing the further development of the mold industry, the five leading enterprise jointly set up mold Constant Field mold company 200 million yuan investment mold built based technology centers were the focus of government support; once the dominant player in the country mold industry in Shanghai, want to revive the former glory of the Shanghai Municipal Economic Commission, the main control center is in full swing mold to build an area of 1,500 acres, modern industrial park will soon die show in front of people; Suzhou New District proposed building a high level with international standards of modern industrial base mold the idea of an area of 2,000 acres ; South China University and the Guangdong Fonda Group signed an agreement, prepared to die city of Changan Town, Dongguan City, played an important cause of mold in southern China R & D base; Shenzhen City in the industrial structure adjustment, the clear will die as the head of the advanced manufacturing industry, investment about 6 billion yuan industrial park building mold; invest 5 billion yuan in Chongqing to build China’s largest, highest standard of automobile, motorcycle mold industrial park, planned in 2035, the annual output value of 3.0 billion; Shantou Plastic Machinery Mould total annual output value of over 10 billion yuan, currently about plastics, machinery and related tooling enterprises with 3,000, most of the companies complete the introduction of Germany, France, Italy and Taiwan, the region’s new CNC mold processing equipment, greatly improved product performance and quality grade . There are a number of other provinces and cities in China (Nanchang, Jiangxi, Shaanxi, Xi’an, Dalian, Yantai, Shandong, Hebei Botou) have to seize our country is becoming a “world factory” great opportunity to create molds Park, brewing industry further escalation of the mold.

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Second, analysis of industry trends mold

1, mold market globalization, the mold further reduce the production cycle

Mold the globalization of markets is the most important features of today’s mold industry is one of the mold buyers and manufacturers all over the world, the globalization of the development of tooling industry to the production process is simple, low precision mold processing enterprises to the technology is relatively backward in productivity than Countries with low migration, mold manufacturing enterprises in developed countries are located in the production of high levels of mold, mold manufacturing enterprises have to face global competition, manufacturers have to die while doing everything possible to speed up the production progress, efforts to simplify and abolishes necessary to the production process, the mold production cycle will be further reduced.

2, Die CAD / CAM to the integration, intelligence, and network development

More complete software modules, while the function module using the same data model and implement integrated management and sharing of information, support mold design, manufacturing, assembly, inspection, testing and production management of the entire process. Some series software includes a surface / solid geometric modeling, engineering drawing complex geometry, advanced rendering industrial design, mold design expert system, complex physical CAM, artistic design and sculpture automatic programming system, reverse engineering system and the complex physical-line measurement system ; mold design, analysis, manufacturing three-dimensional technology, paperless new generation of software to three-dimensional mold, intuitive sense to design the mold, using three-dimensional digital model can be easily used in the product structure of the CAE analysis, mold can produce evaluation and CNC machining, forming process simulation and information management and sharing; the same time as competition, cooperation, production and management of globalization and internationalization, and rapid development of computer hardware and software technology, network Shide Zai die industry virtual design, agile manufacturing technology both necessary and possible.

3, mold technology to high speed machining, hard milling and compound machining direction

With the precision mold to develop in the direction of and large, ultra-precision finishing technology over 1μm and collector, chemical, ultrasonic, laser processing technology integrated with the composite mold in the future will have broad prospects. High-speed machining to the workpiece surface was smooth, save processing time, typically only a step away from 0.0254mm, and sharp point only 0.001mm high, after the majority of high-speed machining of the workpiece surface is very smooth, no fitter further processing. Currently, machine tool manufacturers are keen on the production process and the specially designed high-speed machining center, high-speed processing technology in the United States to reduce or eliminate fitter process is a considerable efficiency measures, this technology in Europe and Japan popular. In addition, hardening of the material processing with a full mold cavity mold processing industry is another important trend. High spindle speed and a small tool radius cutting carried out by the formation of mildly enough torque, can be used to process up to 64HRC hardness of metal materials, because no need for heat treatment, conventional heat treatment and tempering after the offset caused by the heat treatment carried out by the geometric deformation of grinding also do not need, and the technology in Japan, the acclaimed, now in the United States has also been a lot of attention and positive spread in Europe.

With the rapid development of new technologies, foreign countries have emerged mold automatic processing system that the rational combination of multiple machines, with accompanying positioning fixture or positioning disk, a complete equipment, tools and CNC numerical control database synchronization system of flexible with real-time quality monitoring and control system.

4, mold will be large, precision, standardization direction

On the one hand increasingly large part of molding and to improve production efficiency development of “a multi-cavity mold,” led to mold growing large, the other electronic information industry, medicine, rapid development has brought parts of miniaturization and precision, some tolerance precision mold requires less in the 1μm. Another multi-functional composite mold will develop further, in addition to the new multi-functional composite mold Stamping parts, also responsible for layers, tapping, riveting and assembly tasks such as locking, to further improve production efficiency.

Mold standard parts used in developed countries generally cover about 80%, as China’s mold industry, mold will enhance standardization, standardization will be further enhanced mold, mold standard parts of the application and production in the “Eleventh Five-Year” will be greater during the development.

5, the hot runner mold species, mold and adapt to the high-pressure gas-assisted injection molding direction

Mold with hot runner technology can improve productivity and quality of workpiece, and can produce significant savings of raw materials, many foreign plastic mold factory produced more than 50% of plastic molds using hot runner technology, and some have more than 80% The effect is obvious; Gas-assisted injection molding with injection pressure is low, Warpage small, good surface quality and easy-to-wall forming larger products, such as differences in advantages in the premise of ensuring product quality and substantially reduce costs; high-pressure injection molding of resin shrinkage can be forced to increase the dimensional stability of plastic parts; another injection compression molding technology, enables forming a small piece of local internal strain can be less thick Molding shrinkage, while the narrow components for plastic parts can also be injected resin, and used a small injection of power to get good products, these technologies are gradually promoting the use of.

6, very broad prospects for rapid economic mold

Many varieties of small batch production era, people asked mold production cycle as short as possible, so rapid economic development of mold will have broad prospects. Expected in the 21st century, with various superplastic materials to produce molds with epoxy, polyester, or in which the filler metal and glass reinforcement and making simple molds and other production means the ratio of total industrial production will reach 75%. Rapid economic mold include rapid prototyping, surface forming tooling, casting forming tooling, extrusion mold technology and ultra-molded shape, multi-point forming technology, KEVRON steel blanking blanking tooling , mold blank rapid manufacturing technology.

7, high-quality mold materials and advanced surface treatment technology attention

Due to improper selection and use of materials, causing premature die failure, which accounts for more than 45% failure die, so choose the appropriate application of high-quality steel and surface treatment technologies to improve the life of the mold is very important to improve the purity of steel, isotropic , the density and uniformity, and development of more high-performance or performance of a special mold steel, mold steel specifications development, expansion of other high-quality mold materials such as carbide, ceramic materials, composite materials, the application of such a major research focus; use aluminum alloy for mold materials to shorten the molding cycle, reducing die costs, will be faster in the rapid economic development of mold.

Mold surface is the main trends: the infiltration of a single element to the multi-element penetration, complex permeability development, from the general diffusion to CVD, PVD, PCVD, ion penetration, the direction of ion implantation, etc., can be used in the coating are: TiC, TiN, TiCN, TiAlN, CrN, Cr7C3, W2C, etc., while heat means heat from the atmosphere to the development of vacuum heat treatment. Currently laser strengthening, glow plasma nitriding and electroplating (plating) enhanced anti-corrosion technologies are also more and more attention.

8, auto, IT development impact the electronics industry market sentiment dies

China imported the first negative mold growth, mold industry by the “one large and one small” pull, the development of really good the last two years. “A major” refers to the automotive industry, automobile industry refers to not only vehicle, as well as automotive components, such as the United States at present in China for the first time the second largest auto parts exporter, which means that China’s auto mold market has played an irreplaceable role. Its rapid development of mold plays an important role in driving, “a small” refers to the IT electronics industry. Die in 2006 for the 2.047 billion U.S. dollars of total imports, 2.068 billion U.S. dollars in 2005 reduced the 21 million U.S. dollars, for the first time negative growth, stopped the momentum of the expansion of imports increased every year; exports totaled 1.041 billion U.S. dollars, more than an increase of 41.06 percent in 2005, for the first time over 10 billion dollars and imports to reduce the deficit down, is very gratifying.

9, the mold need to further adjust the industrial structure

Although the mold industry and previous years has made significant progress, but there are still many problems. For example, the phenomenon of irrational industrial structure still exist. Structure, including product mix, technological structure, import and export structures, there are different degrees of problems. For example, in the import and export structure, due to the mold design and manufacturing standards and capabilities can not meet the market demand, therefore, die every year a large number of imports, especially high-end products. In 2006 the import and export stamping die, if by weight, priced at 14,913 U.S. dollars / t, and 5,869 U.S. dollars / t, much higher than the import export; while for plastic rubber mold, in 2006 imports and exports were 413,715 units and 1,217,772 units, exports is far greater than imports, while the unit is very different from the poor: the import price of 2532 U.S. dollars / set, the export price 602 U.S. dollars / set, a difference of four times, although the export volume was nearly 3 times the amount of imports, but still below the total amount of imports . That we are still importing large quantities of high quality molds, exports are dominated by middle and low. Therefore, in the long run, the rationalization of import and export trends should be expanded exports and reduce imports, making exports more than imports. Obviously, this also needs to want to be a period of time.

10 management companies restrict the development of mold

Unlike mold manufacturing process management product management, it is the face of unit production of the mold industry, and how digital information management, is very learned. If the mold is not a scientific management, dynamic management approach, we can not guarantee orderly mold manufacturing, rapid prototype Shenzhen mold supplier in time. Meanwhile, each company’s mold products are different, so they need individual management. Those who do well die business, they have a set of unique, for their own management, but that too few companies. Luobai Hui pointed out that the mold business if we do not focus on management development will not continue, and this has seriously constrained the mold enterprise development bottlenecks.

What is Pad Printing?
Pad printing is an industrial process of printing onto for objects with curved and/or uneven surfaces. Pad printing machine has 3 main components: the pad, ink cup and the printing plate (also known as a pad printing cliché.) The ink cup slides over the image etched into the plate and leaves a thin layer of ink in the etched area. The printing pad picks up the ink from the plate and transfers it to the parts by gently pressing down on one after the other. The pad printing plate is the most important part of the printing process; this is where the image is set. How well the image is set into the plate will largely determine of the quality of the printed image.

Types of Pad Printing Clichés
There are three types of plates that may be used with a pad printer: photopolymer printing plates, laser plates, thin steel plates and thick steel plates. Laser plates are designed to be etched directly from a digital file, sent from a computer to a laser engraver. Thin steel plates are chemically etched. Thick steel plates can be either chemically etched or laser etched. Photopolymer printing plates are made by exposure to light, developing and curing, a process that takes a film positive, exposure unit and curing oven.

The Challenges of Photopolymer Plate Making
Making a photopolymer pad printing cliché is a multi step process, which involves making a film positive first and then exposing, developing and curing the plate. There are many variables, things can easily go wrong and they often do. Over the years, the technical support team at Inkcups Now Corp. found that the number one reason for misprints, substandard prints and production stoppages are the various mistakes in polymer plate making process. These step by step written instructions below coupled with video instructions are meant to help people get it right. If you still have questions or problems, feel free to contact the Inkcups Team, we are here to be your partner in decorating projects!

Video Instructions on Making Photopolymer Plates & Film Positives
Here is a link to the FILM POSITIVE MAKING VIDEO for the pad printing plate.
Here is a link to the PHOTOPOLYMER PLATE MAKING VIDEO, which shows how to expose, develop and cure the pad printing cliché.

Written Instructions on Photopolymer Plate Making:
1. Spray the film positive with TONER SPRAY.
2. Cut out the film positive to fit the size of the plate.
3. Remove the protective plastic from the plate.
4. Place the film positive FACE DOWN on the plate.
5. Place in the Exposure Unit, expose to UV light for 60 seconds
6. Remove the film positive from the plate; replace with screen film.
7. Expose to UV light for 60 seconds.
8. Remove the screen film from the plate.
9. Gently rub the plate with Plate Developer for 60 seconds.
10. Rinse the plate with water to remove the plate developer.
11. Dry the plate with compressed air.
12. Place the plate in a Drying Oven for 10 minutes.
13. Remove the plate from the drying oven, put back into the Exposure Unit.
14. Expose to UV light for 10 minutes.

The Best Method for Making Pad Printing Cliches – Laser Engravable Plates Creating photopolymer plates may be the most cost effective method, however it is not the best method. Photopolymer plate making takes 20-40 minutes, the image is second generation, and not as sharp.

There is a fast method, producing superior quality plates: laser plate-making. Laser etched image is first generation (digital image goes directly onto the plate, without the film positive stage); the etch has straight walls and is totally repeatable every time. Laser plate making takes only 3-5 minutes and does not involve any chemicals. Inkcups Now pioneered direct to plate laser technology and has a lineup of Laser Engravable pad printing plate materials to accommodate any application and production requirements, learn more here: www.inkcups.com/supplies/laser-plates/

Here is something I just learned to do…make my own photopolymer plates. With a lot of digging and asking questions along with a ton of trial and error I have found a way that works for me to make a photopolymer plate for printing on my C&P letterpresses. Watch the video to see my work flow from art and negatives to exposing and rinsing a photopolymer plate. I will give you info on where I get my supplies for printing and platemaking as well as what I use to expose and wash out my plates. Feel free to leave a comment or question and I will be more than happy to post responses. I just want to give others the change to have an easier start than I did. www.itsfancy.com
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Agile denote nimbleness. Agile is a light weighted development methodology which is based on iterative development, where solutions evolve from tightly collaborated cross functional teams.

Agile denote nimbleness. Agile is a light weighted development methodology which is based on iterative development, where solutions evolve from tightly collaborated cross functional teams.

Principles of Agile methodology

Agile methodology primarily focuses on Individuals and their communication, Working Software over comprehensive documentation, Customer collaboration over contract negotiation, and responding to change over following a plan.

a) Customer Satisfaction

b) Good team with higher accountability

c) Light weight requirements, flexibility for rapid changes

d) Small and Iterative cycles

e) High degree of communication

An agile process facilitates the customer to have a quick view of the product. Agile process delivers early and often. As a rudimentary system is provided with in first couple of weeks, Customers has a chance to make requirement changes if they feel that what they see doesn?t match with what they envision. Requirements changes dynamically but they strictly adhere to deadlines.

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As agile methodologies are rapid in nature, a team of good players needs to be accommodated. Though all players need not be strong players,players with higher accountability and user involvement is imperative. The team should comprise of developers, customers, and any other business related personalities. The team should be empowered to make decisions.

Requirements have to be light weighted. We can expect change in requirements late in development process. It should be noted that requirements evolve with fixed time scale. This differentiates agile methodology with conventional development methodology. Generally industries go with 80-20 acceptance policy.

Agile methodology advises to develop project in a small size with an incremental nature. Agile is iterative in nature. This nature reduces the risk of what you see vs. what you envision aspects. It also provides effective cost management, and less re-factor cost. Deliverables are given preference over documentation.

There should be a high degree of communication between the team members in order to implement agile methodology effectively. There should be significant interaction between the customers, developers and stakeholder. Just-In-Time [JIT] methodology has to be implemented for successful practice of agile methodology.

Agile methodology provides rapid delivery in a dynamic environment. This incremental nature provides cost-effective behavior for product development. This methodology not only enables to deliver cost effective prototype, but also provides flexible re-factoring. In a competitive environment, business always competes with others business by releasing innovative products in a dynamic rapid world, which can be completely supported in agile methodology.

Reference:

[1] Pavan Gorakavi, Build your project using Agile Methodology http://asapm.org/asapmag/articles/A1_AboutAgile.pdf

Software Product Engineering involves performing the engineering assignment to build and maintain the software product using each project’s defined software development process and suitable methods and tools. The reason of Software Product Engineering is to constantly perform a well-defined software engineering process that combines all the software engineering activities to fabricate correct, consistent software products efficiently and proficiently. This process reaches until the customer satisfaction will be achieved. Here are the some factor’s that make it easier:

EffectiveCommunication:
Traditional outsourced software development has been more in a hands-off mode. However, software product engineering is mostly a similar activity carried out double shore with teams at both the customer and the vendor end working in cycle to achieve the goals. The communication needs to be at all levels – management, leads and the team at both shores so that one hand knows what the other is doing and what the think-tank is working on to achieve the shared vision.

Team Durability:
Since software product development assignments can perfectly run perpetually, it is vital that key team members bond to the product for long periods of time. Products and frameworks usually have proprietary knowledge and a member one year into the product can be twice as productive as a new joiner, twice as experienced. So it is highly essential for an software product engineering organization to be able to prevent attrition from software product teams.

Extensible Design and Reusable Code:
In contrast to software developed one-off, a product sees several generation of versions and numerous branches to convince its direct (end customers) and indirect (professional services, system enablers) customers. So it is really important to make sure that there is a high level of extensibility and reusability built into it, failing which the business logic gets replicated in multiple pieces and it becomes a maintenance nightmare.

Automated Testing:
It is very easy to break an existing functionality while Implementing/fixing the other. Automated unit tests usually come in handy in these situations as they have the requirements encoded in them and can complete a quick regression in a short period of time.

Streamlined Documentation:
With various releases and enhancements in various versions in software products, it is very simple to end up with a pile of documents for each attribute not knowing which one reflects the current state of the software it is therefore important to manage the documentation well to prevent running into these situations.

Implementing the above factors in your software engineering process will very vital in software product development and makes the customer to meet their requirement.

Related Production Engineering Articles

Today I am going to discuss really an interesting topic – crossing the barrier of SLA. This article will give you an insight how important is a customer relationship and how it is playing vital role not only in your carrier but also for your organization and how six sigma help us to achieve this.

As we all aware that SLA is nothing but service level agreement between customer and service provider. This document signed by both the parties. But here I am not going to discuss what a SLA is. I would like to discuss how we cross the boundaries of SLA and what the challenges we faced to do that are.

We have done this for a global auto major. From the end of 2006 auto industry was not doing that much of great like it did earlier and planned for cost cutting. As a cost cutting measure they planned to outsource lot of IT works to Asia pacific reason from the US.

 The managers from different levels of this company in Asia pacific region wanted to implement a new concept, ITIL in their IT to reduce the cost in more efficient manner (Another article on implement ITIL for global auto major soon going to publish here ).

I am the fortunate one who got an opportunity to implement this task. We have around 5-6 different service providers (Vendors). First hurdle we got the confidence of the resources to work on this model as none of them has worked in ITIL model prior to this assignment including me. Fortunately I was trained in my company ITIL 2 earlier. I could still remember once I selected for this tasks I was told by one manager that to success of this we just need to change our mindset and remaining things will follow smoothly. 

Once transitioned completed the real problem start. Whatever tickets we received all became SLA missed. This creates a serious concern for both management and customer. Things are getting worse in every day. Customer started threatening to us to pullback the project to US. This project deals with quality of the car and has lot of metrics information. This was the most prestigious project in our portfolio out of around 50 project transitioned to Asia pacific region and capability of this region was all depend on this project.

Management was very clear that any how this project should stay with us. Suddenly one new problem started. Every month there is a data load for this project from different external/internal agency or applications. We were unable to load the data. The reason behind this was network latency. I have provided a solution for this issue and it resolved.

Now we got the real problem. As data load was a real complex process which includes A-Z we were struggling to do this job by CTQ. It was taking almost 3-4 weeks every month instead of taking 1 week which was CTQ.

What we did to overcome this problem…

First we spoke to customer regarding the various issues we faced and convinced them to change all tickets raised during data load to Business support/Customer support ticket and here we were in a position to avoid 60% tickets as SLA missed. But problem still persists and as load taking longer time customer were willing to take back the project.

Then we introduce a 6 sigma Black Belt project which not only change the whole scenario but also inspired me in 6 sigma.

We found couple of key points which were outcome of this project

Most of the time resources do not send the update to customer properly. No proper communication between external/internal agencies about the data. As customers were spread across different geographies there was a huge time lag of confirmation in different stages of the data load. This is also important because one process output is input of other process. So every stage we need confirmation from all the customers to proceed further. There was no proper process to execute the load which was created.

The outcome of this project increase a sigma value from 0 to 2.7 in couple of months and load time reduce to 5-7 days only.

We had involved customers in all phase of the projects so that they can fill a part of it. We have setup couple of other small processes also like periodic feed back, pre load meeting, and pre load check list and so on and for past one year it is running fine. Now customer has a great confidence on us. Earlier in each status meeting there were some escalations surely and now we used to ask them “how is the weather there?”, “How you spent your holiday?” What we are planning to do in this weekend etc.

Below is the improvement of sigma value of Black belt project which we can measure but what we cannot measures are

Customer confidence Satisfaction for resources for overcomes the hurdle. Satisfaction for management for providing a new direction towards ITIL. Lesson learnt for common mistakes. Motivated towards process  and quality

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Forming metal refers to the process of taking a piece of metal in one form and manipulating it into a new shape. Metal is formed without adding or taking anything away from the original shape. Basically metal can be formed by subjecting it to heat or by applying mechanical force. Heat can be used to melt the metal completely at which time it can be molded into a new shape. Heat can also be applied to make the metal malleable and more susceptible to the use of mechanical force to shape the metal.

The downside of the Rainbow vacuum cleaner is that the machine can pick up a mildewy smell if not maintained properly. Here’s some tips from preventing your Rainbow Vacuum Cleaning from developing a mildewy odor.Die casting is an example of adding heat to melt metal and mold it into a new shape. With die casting, high pressure is used to force molten metal into mold cavities. The roll form die process is a modern example of the die system. The second way of using heat to manipulate metal, as mentioned above, is to heat the metal until it is malleable. An example of this process is hot forging, or heating up the metal and then using tools such as hydraulic presses to reshape the metal while it is at a forging temperature. The final way to manipulate metal is through pure mechanical force. The roll forming process is an example of the mechanical force used to bend metal into a specific shape.

Dump the chamber after every vacuuming session. When I first bought my Rainbow vac, I made the mistake of leaving the water in the chamber for several days at a time, reasoning that it wasn’t “dirty enough” to empty. It didn’t take long at all for the evaporating moisture to mildew up inside the machinery. Emptying the chamber after vacuuming prevents mildew from forming in these areas.

Let the vacuum run without the water chamber for a minute or so for a speedy air dry.. This tip came from my Rainbow Vacuum repair guy who suggested air drying the machine after vacuuming. Air drying is done by removing the water chamber and then turning on the power for a minute. Metals come from mineral bearing rocks known as ores. When ancient people began to discover that adding heat to rock ore would release the metallic properties from the rock, societies began developing industries. Throughout history, cultures who possessed the metals, such as copper and tin, and the know how to develop the metal into tools and artifacts, were the more prosperous nations. Metal had value back then, and was the mark of progress. Today, metal continues to be valuable as evidenced by the fact that an entire industry of metal workers exist solely to shape metal into usable objects. Over the years as technology and the demand for metal objects have increased, the methods for forming metal have also progressed. Today, several types of machines have been engineered to help form metal into precise shapes and sizes.

Clean and air dry the water chamber thoroughly before replacing. Mildew and mold can form in the dirty crevices of the water chamber. Before returning the chamber to the base of the machine, be sure to clean, rinse, and air dry it thoroughly. Remember to also check the hose intake area for snagged particles.Metal working can generally be divided into the forming, cutting and joining categories. Forming is the process of changing the shape of a piece of metal by manipulating it into a new shape without removing any of the metal material. Cutting, as the name suggests, is the art of shaping metal by removing excess material and cutting a piece of metal into a specified shape. Joining, on the other hand, consists of forming two pieces of metal together by welding, or melting the two pieces being fused and adding a third, filler metal, to basically glue the shape together. Although all three of these methods are fascinating, this article takes a particular interest in the process of forming metal.Add a bit of vinegar to the water while you vacuum forming machine. If the machine has a lingering mildew odor that won’t go away, pour 4 ounces of vinegar into the water chamber the next time you vacuum. The vinegar will deodarize the machine and leave it smelling fresh.

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We are the Italian professional manufacturer which has 25 years experience collect industry with design, rapid prototype, precision process, mould making(plastic mould, die-casting mould), plastic injection\zinc, aluminum casting in China. Our company own many CNC milling machine of import Mitsubishi which can process 2 meters mold, Injection machine capability achieve 1600 TON, we have wire cutting that can process 1.5 meters large parts, CNC spark working machines and high-speed CNC, aided design and inspection equipment.

Rapid prototyping is a procedure of software development in which physical objects are robotically built by means of SFF or solid freeform fabrication. In the process of rapid prototyping, a prototype or functioning model can be built rapidly, and tested for its functionality, performance and output. The latest features or ideas can be illustrated well in the prototype and early user feedback can be gathered with regards to the product. There are various advantages of rapid prototyping.

Benefits of Rapid Prototyping: Significant advantages of rapid prototyping include reduction of project cost and risk. Generally, one or more prototypes are developed in the process of software development in a series of incremental and iterative steps. Every prototype that is manufactured is based on the previous designs’ performance and it is a corrective process through which the past design defects or problems are corrected. The product is readied for production when the prototype is refined as per requirements and meets all the design goals like manufacturability, robustness and functionality.

Our Rapid Prototypes fields cover automobiles, electronics, bath equipment, toys, kitchenware, telecommunication equipment and living goods. After 19years of development, we have built cooperative relationships with many foreign invested enterprises and well-known domestic corporations through our specialized workmanship and the best after-sales services.

In the Plastic/Zinc, Aluminum casting product, we have developed hundreds of custom products for clients of America, Britain, Germany, France, Italy etc. Include: spoon, draw knife, potato clamp, apple cutter brush, car met, light frame, toilet seat cover, shower, electric wheel, telephone cover, medical anti-static operating vehicle, shoe rack, water pipe, refrigerator button, pizza case, wagon wheel, etc.

OEM

OEM stands for Original Equipment Manufacturer, but this can also called as Factory Original when it comes to Automobile parts, Bicycle parts, & even Technology Parts. This OEM creates reference to the company / organization that initially manufactured the commodities that consumers are buying. We offer prototype until product manufacturing services as long as you offer designing sketches to us.

ODM

The OEM_ODM manufacturer wants to complete definite criteria prior to you obtain your powder packaging machine and vertical packaging machine from us that suit your equipped requirements. On these conditions, the most important one is that the manufacturer needs to complete is a obligation on the supply of spares and technical support for a reasonable period after the installation of the machine in your manufacturing facility. If you only have ideas, we can offer the design of appearance and the

structure and make molds for you. After having got your final confirmation,

we will start product manufacture.

Please be assured, customer’s drawings are kept confidential, we can sign confidentiality agreement before you offer designing sketches to us.

Our core values everything starts with customer’s benefit.

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Gone are the days that producing a prototype normally took long hours to finish. It can be recalled that creating a prototype typically ends up in a lengthy process and skilled workers painstakingly do the labor hence requires high-cost. The need to create a speedy process to automate the construction of physical objects into sturdy physical models, commonly known as additive manufacturing, brought into existence. The solution is rapid prototyping with faster and easy-to-use 3D Printer. The breakthrough of rapid prototyping machines has become an answer for many plastics manufacturers to fabricate quality-produced parts comparatively in minute amounts.

How does a 3D printer work? The technologies used for 3D printing varies throughout the developers of rapid prototyping machines. Nowadays, the principle of inkjet printing system vastly applied in making 3D printers due to its fast turn-around in creating models that closely simulate the appearance, feel and functionality of product prototypes. Though they look like the copiers and printers, we see outside, 3D Printer is something completely different because these are not ink-on-paper printers. The process begins from the print head whereby thin droplets of materials deposited onto a surface, one on top of another in a successive manner until a 3D model is completed. The diameter of 3D particles deposited is around 50 to 100 micrometers. Industry leader 3D Systems Corp based in California pioneered this.

The use of 3D printers has been widely used even ordinary consumers. Well-established applications include design visualization, metal casting, prototyping and CAD for mechanical and design engineers’ projects. For architects and civil engineers, creating entire building prototypes made possible for them to detect failures on their designs. Recently, it has jumped off into a new realm in biotechnology to print a 3D Printer of body parts from cells. It is a strikingly promising application due its capability of producing tiny prototypes thereby does not need to borrow of human parts from someone else. Other applications include making consumer toys, reconstruction of fossils, replicating ancient artifacts among others.

Such development of 3D printing recognized as one of the most tumultuous emergent IT technologies. From the highly expensive printers as it was first introduced, costs of machines are highly dramatic in the sense that it is very affordable due to its falling prices. Evolution of 3D printing has been positively looked forward by many technologists because most of the changes are widely accepted by many consumers. Aside from the big players of 3D print technology such as 3-D Systems, Desktop Factory and Z Corporation, companies actively involved are HP, Canon and Xerox. Other major 2D printer technology providers are still yet to be determined if they want to be engaged in this highly exciting technology.

Back in the day, people had to make models by hand. This was a painstaking process that required a steady hand, a keen eye for detail, and a lot of time. Because it took so much time, it was also expensive to make models, which meant that you had to be pretty sure about a design before making it come to life in a model. Also, if the design were unsuccessful, you would have to start the entire tedious process all over again. Fortunately, modern technology has changed the way that models are made. Now, 3d printers can be used to create models quickly, accurately, and affordably. 3d prototyping is becoming more and more popular, and it is easy to see why.

3D prototyping is a process by which a resin model is made from CAD (computer-aided design) files. These models can be made at varying levels of detail, although making a higher-resolution model will take longer to make. Instead of having to pay minute attention to detail, you can let the 3D printers do the thinking for you. The resulting models are accurate, detailed, durable, and can even be painted to give you a better idea of what the finished product would look like.

Models made by 3D prototyping are created from thin sheets of resin. While a typical resin thickness for an application like this is 0.004″, higher-resolution models use even thinner resin, 0.002″ to make sure that the details really shine through. Most 3D printers will allow you to choose the level of detail that you want in your model, but you should keep in mind that higher levels of detail will require more sheets of the thinner resin, as opposed to fewer sheets of the thicker resin. This process will take longer; so make sure to time the prototyping process accordingly.

Using 3D printers, even for higher-resolution models, is a great timesaving measure. Gone are the days in which models were expensive and took a long time to produce. These days, making models through 3D prototyping is so easy that more and more people are doing it. It is growing in popularity simply because it’s a better process: faster, easier, and cheaper. It can drastically cut down on the amount of time that it takes for you to go from model to finished product in development. You should be sure to take advantage of the technology of today.