Lean Tool validation for injection molding means developing a more efficient process that benefits the environment; Reduces CO2, and saves costs  Bozilla uses “cutting-edge” proprietary techniques developed over 21 years in the injection molding industry to determine if a tool can be optimized and brought back to life in its most efficient state

A typical scenario entails a company contacting Bozilla to make a tool more efficient or bring a tool back to life  We would ask them to send us everything about the tool, including CAD drawings, 3D part and tool drawings, machine process settings, current tool status, and other pertinent information about the tool

Bozilla will investigate all areas of inefficiency, outline suggestions, and provide a proposal  During the beginning phase, there will be no up-front cost  The company then determines which recommendations can be practically implemented, and Bozilla provides a cost and time estimate  Should the customer accept the proposal, the work can begin immediately

Some examples of tools Bozilla has efficiently improved include those that have been cut wrong (tool dimensions did not match part specifications/dimensions), fouled cooling channels,  a poorly designed feed system(both hot and cold), cycle times that are excessive or are known to be inefficient and even tools that have been sidelined due to inefficiency

Once the project has started, the type of work performed is analytical where Bozilla models the current design and conditions in a virtual world using Autodesk Moldflow Insight

Initially, our team would identify areas of the process that can be optimized, make those changes and continue to further optimize the process  Once the process has been deemed efficient (based on the tool design, coolant flow rate, and other factors), the customer will have an opportunity to review and make as many changes as possible, which may or may not include tool modifications (such as adding cooling lines) It is not always apparent that a tool is underperforming unless a thorough investigation is performed   Each potential issue is identified accordingly, and proposed changes are provided to create a streamlined, lean running tool that will be lean and profitable

Some examples of proposed changes may include instrumenting the tool correctly,  determining pump efficiency, reducing cycle times, increasing temperature control, minimizing process variation, reducing energy consumption (creating less CO2),  recapturing costs from tools