For Milacron India Pvt Ltd (MIPL), a leading higher-tonnage injection molding machines manufacturing company, a strategic approach helped overcome challenges in its endeavor to offer high-performing and cost-competitive products tailored to meet customer needs.
Higher-tonnage injection molding machines are a promising product offering from Milacron India Pvt Ltd (MIPL). However, the company faced challenges from competitors in the market, and in order to become a market leader as an original equipment manufacturer (OEM) for higher-tonnage injection molding machines, it was essential to provide high-performing products at competitive costs while maintaining the best quality. A strategic approach was thus required to overcome the challenges encountered. Thus, MIPL implemented a systematic plan to meet customer requirements and address these challenges effectively.
In our endeavor to close the gap between our customers and ourselves, we initiated a comprehensive customer survey. Through this survey of higher-tonnage machines, we gained valuable insights that highlighted the significant area of improvement within the clamp unit of our plastic processing machines. This feedback from our customers provided us with a clear direction.
As a prominent manufacturer of tailor-made plastic processing machines, it is crucial for us to adapt to the changing market conditions and meet the evolving demands of our customers. We recognize the importance of delivering machines on time and ensuring performance. To achieve this, we had to curb
the cost and gain an edge over our competitors.
Solution generation, innovation, and complexity
The customer survey provided us with valuable insights and feedback, allowing us to focus on the clamp unit to align with them.
During validation, we covered all real-world operating conditions and the anticipated loads and constraints in the defined application. The results were found satisfactory in all segments. |
The outcome exceeded MIPL's expectations with an impressive reduction of an average of 22% without compromising the machine’s performance and specifications. |
To reduce the weight of the clamp unit casting, we initially introduced a compact design. However, the weight reduction achieved was only an average of 10 percent in the first design, falling short of our target. In response, we conducted brainstorming sessions again and performed Finite Element Analysis (FEA) at an optimum level to identify further opportunities for cost reduction. The outcome exceeded our expectations with an impressive reduction of an average of 22 percent without compromising the machine’s performance and specifications.
Based on customer and market requirements, we developed best-in-class clamp force and Tie bar spacing against our competitors as per the below table.
After successfully achieving all our targets and thoroughly evaluating the design with FEA analysis, we moved on to our next crucial step: manufacturing the clamp unit based on our finalized design, installing it at our on-site location for a specific time, and validating it as per standards and customer requirements. During validation, we covered all real-world operating conditions and the anticipated loads and constraints in the defined application. The results were found satisfactory in all segments.
We faced several challenges during the implementation of this project:
DEVESH DUDHWALA Deputy General Manager – Design |