A publicationof the ARBURG Group

Number 10 Spring 1999

Information oninjection mouldingmarketing and technology

From Western Forts to Fairy Castles: Playmobil

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K ‘98Looking back on K’98

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Karl Hehl Eugen Hehl

C o n t e n t s

ARBURG architectureInvesting in the future

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ARBURG applications technologyAn information source for injection moulding technology

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ARBURG qualityComprehensive checks

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ARBURG technologyBottles made easyTech TalkSELOGICA for multi-component machines

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ARBURG organisationTeam Allround: new working methods

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ARBURG subsidiariesPolska: a link with Eastern Europe

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User reportFrom Western Forts to Fairy Castles

After its Golden jubilee year, which also included what we con-

sider a highly successful K fair, ARBURG is making the most of

the excellent trends of this year and is full speed ahead with new

work. Those who know us know that we never rest on our lau-

rels, but always meet the challenges of the future with a positive

approach.

So it will come as no surprise that our company has in the past

year achieved outstanding results in comparison with previous

years. ARBURG achieved DQS (German Association for certifica-

tion of Management Systems) certification in accordance with

DIN EN ISO 9001 and 14001, obtaining dual certification.

Our successful Jubilee edition ALLROUNDER C JUBILEE replaced

our former C-series at the beginning of 1999 due to great de-

mand: the design of tried and tested machine technology and

the latest SELOGICA operating philosophy were enthusiastically

received.

With our ALLROUNDER C, S and 221 K ranges, we offer a stream-

lined ultra-modern range of models of uniform design and uni-

versal SELOGICA operating platform. With this range we have

modified our old, much-copied modular system in a completely

different way.

There has been progress in other areas of ARBURG’s activities

too: the new building for our ARBURG production workshops will

see the dawn of a new age for our company, both architec-

tonically and in terms of machine technology.

We hope you enjoy your latest edition of ARBURG today and that

you find it informative.

ARBURG TodayEdition 10 / Spring 99ARBURG Group’s Customer Magazine

Issued by: ARBURG GmbH + Co

Editor:Dr. Christoph Schumacher (resp.)

Editorial team:Dieter Dissel, Juliane Hehl,Martin Hoyer, Peter Mechler,Roland Paukstat, Bernd Schmid,Jürgen Schray, Renate Würth

Collaborators on this edition:Uwe Becker (text), Andreas Enderwitz(photos),Frank Himmelsbach (photos),Peter Mechler (TechTalk), MarkusMertmann (photos), Björn Oldsen (photos),Martina Schrenk (graphics)

Editorial address:ARBURG GmbH + CoPostfach 110972286 Loßburg

Tel.: +49/7446/33-3149Fax: +49/7446/33-3413E-mail: today_kundenmagazin@arburg.comwww.arburg.com

PUBLISHED BY

Reproduction, including in the formof extracts, subject to consent

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K’98 was a total success for ARBURG! And not just because of a knock-out stand.The image of the future for a major impact with the latest technology in a uniform design!

K‘98

An atmosphere of well-being: it was not untillate into the eveningthat peace descendedon the ARBURG Jubileestand. The standthronged with visitorsthroughout the entireday. Both the uniformdesign machine rangeand the overall presen-tation, achieving an im-pressive combination ofpast, present and fu-ture, drew tremendousapproval.. .

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A R B U R G a r c h i t e c t u r e

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Investing in thefutureARBURG II – A project thatwill see the dawning of anew age

This project is much more than anew hall or extension. It is a com-pletely new plant that will liter-ally rise from the ground next tothe existing company complex bythe turn of the millennium.

Major efforts are needed tocreate the new production unitsand 150 new jobs. In total, thebuildings will cover an area of

some 20,000 m2 by the end (about40,000 m2 of useful surfacearea), with conversion of some240,000 m3. ARBURG previouslyhad around 100,000 m2 of build-ing area, which means that theexisting plant will be expanded bysome 20 percent.

With the cornerstone laid byARBURG associates on 14 August1998, the starting shot was firedfor one of the largest coordinatedbuilding projects that the Loßburggroup of companies has under-taken.

Excavations for the first part ofthe project took 12 weeks. In to-tal, some 150,000 m3 of earth hadto be moved. Looking to the fu-ture, the building owners decidedto double the volume of earth-works, to obtain the land neces-sary for future development.110,000 m3 of rock excavationwas undertaken by the earth-works contractor. ARBURG is in

fact building on rock and into theearth for logistical reasons. Thecompany is thus keeping to itspolicy, blending the new plant ascarefully as possible into thelandscape.

Data and facts that speakfor themselves

The building project is dividedoverall into five different projectstages (PS). It will start with the“Pipework” to provide the neces-sary connections with the foulwater and rainwater drainagesystems between the existingplant and the future extensions.

Building stage 12 will laterhouse the wet lacquering andpowder coating lines for machinecomponents, building 20 willThe fourth Hehl generation at the cornerstone

ARBU

RG II

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ers and track-mounted vehicleswere in operation on the site.About 80,000 m3 of the stone wasbroken up on site and re-used ashardcore. In addition, a further10,000 tonnes of variegatedsandstone blocks were set asideand offered for garden construc-tion and landscaping.

Project 12: Wet lacqueringand powder coating line

The useful surface area of thisbuilding will cover some 5,000 m2,with a prefabricated concrete boxroof construction with spans ofabout 28 m. The entire bay will besprinklered and equipped with agoods lift of 16 tonne capacity.The existing powder coating in-stallation is scheduled for a movein summer 1999. Here again,things will have to move quickly:production shutdown of just twoweeks is planned during theworks holidays.

house the “works link” betweenARBURG I and II, designed as alogistics bay with a ready-builtstorey to the office tower, projectstage 21 covers the assemblybay with a total surface area of80 x 96 m plus 16 x 170 m accessroad. Other service buildings willalso be constructed.

As far as building costs areconcerned, Chief Site ManagerManfred Wolfer, the authorisedrepresentative of the buildingowner, Hehl International GmbHprefers to keep a low profile.A figure running into tens ofmillions DM seems realistic, butincluding all the production unitsanother figure is likely to beadded before the decimal point.

Despite this awesome task,the actual buildings should infact, according to the architect,be completed in just two years.

Impressive figuresAsphalt work for roads and

parking areas around the newbuildings will alone require some12,000 m2 of surface area. Theoverall excavation work amountsto some 300,000 m3, with theearthworks contractor excavating4000 m3 each day. For compari-son, a large family house requiresabout 300 m3, i.e., a volume rep-resenting some 1000 houses willbe excavated in order to buildARBURG II. The land on which thenew work bays will be built corre-sponds to an area correspon-ding to four football fields at150 x 230 m approximately. Some20,000 m3 of concrete will be re-quired to build the bays to thissize.

ARBURG II will be foundedon variegated sandstone

The project will involve mov-ing vast quantities of variegatedsandstone from the «Loßburgerplate». At peak times, six dumpertrucks (HGV) with a tare weight of40 tonnes each (total weight some70 tonnes) as well as scoop load-

Project 20: Logistics bayThis part of the building covers

a useful area of 6500 m2, offeringfurther storage facilities ofaround 5000 m2. The basement ofthe bay houses a sprinkler tankwith a capacity of 1500 m3. Acomparison will again serve hereto illustrate the size of this: aswimming pool of external di-mensions 20 x 10 x 2.5 m has avolume of 500 m3. With a waterstorage capacity of three timesthis, up to 20,000 sprinkler headscan be supplied.

Project 21: Assembly bay80 x 96 m

The assembly bay will have thelargest useful surface area by farat 18,000 m2. A converted area of131,000 m2 will be adjoined byan access road. A total of 80 (!)crane installations with a carry-ing capacity of between 2 and32 tonnes will be distributedthroughout the bay. At this pointit is interesting to note that thecompany has also looked to thedistant future in its overall plan.The idea is to be able to repro-duce this building section as an“ARBURG module”, without re-designing each time.

«Low heating energy bay»This building will be excep-

tional in other ways too: ARBURGwill be using an energy technol-ogy developed in close conjunc-tion with the Fraunhofer Gesell-schaft. Loßburg will have a lowheating energy bay.

A highly complex facade con-struction method and buildingtechnology and the use of wasteheat from the production lineswill help conserve energy re-sources.

Disposal buildingsThe building measures are

complete, with the disposal build-ing designed for 14 containerspaces and one large container.The building design is a coveredrotunda structure with an exter-nal diameter of 42 m. The floor isdesigned as a concrete structurethat is impermeable to water, inview of the use of the building.

The extensions for theARBURG II complex seem mere“details” after all these figures.The plans include a large garagefor the vehicle fleet, a servicecentre in which trades workingin-house (joiners, locksmiths,painters, bricklayers) will be ac-commodated with their work-shops, and a gate-house with anew access. The guards will thentake over the task of logisticsmanagement. Access to the worksarea will have hard-shoulders forHGVs to prevent traffic problemsarising from the outset.

A decisive step into thefuture

With the cornerstone laid forARBURG II, this represents a verydecisive step into ARBURG’s tech-nological future. The expansion ofproduction capacity was neces-sary due to a strategic decision bythe company of exceptional im-portance: in future, machineswith a mould clamping forcecapacity of up to 4,000 kN will beproduced. This will mean differ-ent, larger and more flexibleproduction facilities.

Or in the words of Eugen Hehlwhen the cornerstone was laid:“We decided to make this far-reaching investment and achieveour great plan true to the oldsaying: ‘If you don’t grow, you getsmaller’.”

U s e r r e p o r t

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Brandstätter GmbH + Co. KGwhich is based in Zirndorf.

According to them, the successof the Playmobil range started in1974 with the ARBURGALLROUNDER. Out of this, afriendly partnership developed,reflected amongst other things insales of more than 250 machines.

The roots of the Playmobilmanufacturers go back to 1876,when Andreas Brandstätter found-ed the firm of the same name in

Fürth in Bavaria. The first prod-ucts made were cashbox liningsand locks, and then in 1908 GeorgBrandstätter, the son of thefounder, took over operations. Itwas at this time that the companyadopted the brand name “Geobra”,made up of the first syllables ofGEOrg BRAndstätter’s first nameand surname.

The move to Zirndorf, wherethe firm still has its head offices,took place in 1921. According tothe trade register, Geobra’s busi-ness was the “manufacture ofmetal goods and toys and themarketing of these”.

The arrival of Horst Brand-stätter in the firm in 1954 her-alded a new era. The companydiscovered plastic as a material initself and for production.

Just four years later, the com-pany achieved major success withthe manufacture of hula hooprings. The production methodused to make the rings could alsobe modified as a blowing methodfor making toys. Pedal car trail-ers, boats and racing cars as wellas piggy-banks were now addedto Geobra’s production range.

Flexibility as the basis forsuccess

Flexibility was the or-der of the day as thecompetition was not farbehind. Structural foamparts with the corre-sponding machinery

and tooling were an-other stalwart.Ceiling panels, children’s

desks, shop fittings, tennis rac-quets and even water skis wereall included in the productionlines at that time, which the com-pany sold in large quantities.

The oil crisis at the beginningof the Seventies and the conse-quent shortage of materials, dras-tic increases in the price of plas-tics and attendant pressure oncosts from low-wage countries

From Western Fortsto Fairy CastlesHow can you be a bike rider,an Indian, a Western hero, apilot, a knight, an adven-turer, a train driver and atrucker in less than an hour?

Easy – it’s child’s play! Just aslong as your children havePlaymobil at home. And Dad cango back to his boyhood too!

The company responsible forthe continuing success of thePlaymobil brand name is Geobra

created major difficulties for thefamily firm.

Introducing new ideas to com-bat a situation such as this is notthe usual path to choose, but thatis what Horst Brandstätter did. Heresolutely put a new plan intoaction, a system toy that couldconstantly be added to with newfigures and scenes, with smallparts that made the most of ex-pensive plastic.

Playmobil was born, and wasfirst introduced at the interna-tional toy fair in 1974. Afterinitial scepticism on the part ofbuyers, demand from children andtheir parents produced successwithin the year, which is stillholding good today and has longhad no parallel in the German toyindustry.

Playmobil in figures

Just a few years after the intro-duction of Playmobil on the mar-ket, the company had the highestturnover in Germany for toymanufacturers and has stayed atthe top ever since. By 1997 thegroup was employing 2,200 peo-ple worldwide.

There are European Playmobilmarketing firms in France, Eng-land, Benelux, Italy, Greece andSpain. These will be further ex-tended by locations in the USA,Canada and Mexico to cater forthe American market. The Brand-stätter Group also includes thecomputer firm Hob Electronic, themould-making firms Brandformand Inmold and two foreign pro-duction plants in Malta andSpain.

1997 was an exceptional yearfor the Brandstätter Group in tworespects. Not only was Playmobilable to sustain 13% growth in thegeneral downward trend of theGerman toy market, but theconsolidated group turnoverpassed the half a billion mark at504.1 million DM. Playmobil salesworldwide of 440 million DM in-cluded some 60% from abroad.

Playmobil is now sold in 65 differ-ent countries and at internationallevel is a best-seller in the toymarket.

Playmobil’s market share inGermany has increased by 6%. In1998 the toy system is as up todate as ever. With the SystemXproduct range, the RC train thatdoes not require connectors andthe constantly updated toy range,the challenge of the increasingcreative demands of the 3 to10 year old sector are met, elimi-nating the boredom factor.Playmobil is now on the Internetand you will soon be able to usethe system with a computer: with

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CD ROMs children can enter thevirtual Playmobil world.

An outstanding systemThis educational toy has re-

ceived official recognition andpraise both nationally and world-wide over the years. Since 1974,some 1.4 billion figures have beenproduced. If these were put end toend, they would reach nearlytwice round the Earth.

Playmobil dream toys are madeof plastic – but why? Because thisis the only material that lends it-self to such a wide range of func-

tions and details. This is also thelink for the long-standing coop-eration between Geobra Brand-stätter and ARBURG.

This top quality mass produc-tion of small injection-mouldedparts is ARBURG’s domain. Sincemanufacture of the Playmobilstarted, both companies havebeen working together. Today asin the past, only top qualityplastics are used, which meet thehigh requirements for stability,functionality and hygiene. Thematerials are neutral and do notproduce any harmful emissions,they are perspiration proof andorally safe, and meet all the re-quired guidelines, such as thosein food legislation.

Collaboration above andbeyond machinery

Right from the outset collabora-tion between Brandstätter andARBURG went beyond just thesupply of machine technology.Support in applications was in-creasingly required to coordinateALLROUNDER machines, periph-erals and tools.

This is why not only theDietenhofen works in Germanyhave ARBURG machines, but alsothose in Spain and Argentina andMalta. Playmobil is also producedunder licence in England, Greece,Korea and Mexico onALLROUNDER machines.

The machine range used byGeobra Brandstätter now includesALLROUNDERs with the latesthigh performance SELOGICAcontrol system. As Karl-HeinzJedamzik, the Playmobil Techni-cal Manager, says, “Without ex-aggeration, we can say thatARBURG has set an example forinjection moulding machine manu-facturers in terms of service, thesupply of spare parts, training,customer support, etc.”. And thelatest generation of ARBURG ma-chines, the ALLROUNDER S range,also finds favour with Jedamzik:

“The latest generation ofALLROUNDER machine technol-ogy is a complete, well thought-out and functional system solu-tion, from injection moulding ofplastic parts to stripping andselection”.

According to the technicalmanager, the SELOGICA sells it-self with its easy overview ofprocess parameters and its func-tional design. Other plus factorsare the excellent display of thecycle process and graphic repre-sentation with modern symbols.“Overall a user-friendly, ergo-nomic control system” is howKarl-Heinz Jedamzik summarisesit.

Special machines to solvespecial tasks

The Playmobil production linesalso include special machinetechnology for special tasks. TheALLROUNDER basic configurationis already very sophisticated anddesigned for automated injec-tion moulded parts production.Removing of parts from the mouldis handled either fully automati-cally direct or, for correspond-ingly larger parts, by mould-strip-per robots.

A pallet system custom-designed for Playmobil require-ments handles the finished parts.The blowing agent injectionmoulding system used as a specialsystem also requires a speciallycooled tempering process formould cooling.

Automation for easiermanufacture

The associated machine peri-pherals are supplemented by acentral conveyor system withmaterial separators on the ma-chine concerned and colouringunits for direct colouring of themaster batch. The material issupplied from 17 silos each of60 tonnes’ capacity via pipeworkand drying stations to the ma-chines.

Small ideas with a bigimpact

If you are going to deal withtoys, you also need to see how itworks. So anyone visiting Zirndorfshould not miss out on a couple ofhours in the «Playmobil FunPark». 1000 m2 are devoted tomaking children’s dreams cometrue – and, as we said, not justfor children. The limits of this“play system” have already beenexceeded with visitors from manyareas in the holidays. As HorstBrandstätter knows all toowell that his best customers– children – need to be spoiledand their enthusiasm won, anextension to the park is alreadyunder way. An attractive outdoorplay area is planned, with adven-ture golf and lots of interiorchanges. The entire complex isscheduled to re-open in summer1999, remaining true to the styleof Playmobil’s 25th birthday.

ARBURG is also involved in thesuccess of Geobra-Brandstätterand thus the success ofPlaymobil. In November 1998 afurther four ALLROUNDER S ma-chines were delivered to the com-pany, and these are already inoperation in the injection mould-ing works.

“Innovations for Playmobil are ofcourse also planned for our Jubi-lee year in 1999”, Karl-HeinzJedamzik informs us.

“But it is too soon to talkabout this yet – it will have to bea surprise. Suffice to say thatARBURG’s ALLROUNDER ma-chines will be used for these.”

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Apart from the machine fleet,it is the production of the requi-site injection moulds that con-stantly requires new investment,running into 2-figure million DM.The figures for 1997 highlightthis: for the production of newmodels and the replacement ofworn moulds, 419 (!) new injec-tion moulds were required just forthat year alone. Brandstätter hasabout 65% of these moulds madeby companies in its own group,Brandform in Zirndorf and Inmoldin Malta, including a large numberof complex multi-componentmoulds.

Meeting future challengeswill be child’s play

Just over 70% of Playmobilproduction is handled in Ger-many. In order to meet a marketwith increasing demand, GeobraBrandstätter is relying on sensible

rationalisation measures. This in-cludes optimisation of productionprocesses, reducing throughputtimes and improving the group’swork by increased individual re-sponsibility.

Constructional measures arealso proposed. In Spring 1998,the extended, upgraded injectionmoulding plant in Dietenhofenwas incorporated in the produc-tion process. A total of 65 of thelatest generation of injectionmoulding machines were in-stalled at this works. The injec-tion moulding plant thus nowhas 172 microprocessor-control-led machines and thereby is themost modern in Europe.

In 1998, total investmentsamounted to 34 million DM. After38 million in the previous year,investment plans remain at a highlevel to ensure the company’sfuture.

howkn

owA R B U R G appl i cat ions technology

related function and a second in-ternal function. Direct customersupport is provided by practicaltests in-house or at the customer’spremises. Test injection mouldingcan be carried out in the demon-stration hall with test moulds forcustomers, who can also partici-pate and check and optimise anycomponents as necessary forsuitability with the engineers con-cerned.

The engineering departmentalso works on optimising methodand process-related measures inthe machine tool and materialssectors. How can new materialmixes or compressed cycle stagesbe used to increase efficiency inthe various injection mouldingtasks? – this is all part of its dayto day work.

In addition the group developssolutions for new injection mould-ing techniques and forward-look-ing technologies, in conjunctionwith the AT designers. Finally, en-gineering department personneltrain customers in commissioningand give them instruction on newcomplex control and handlingtechnologies.

This department also handles“operational requirements”. Thedemonstration hall produces in-jection moulded parts that areused to make ALLROUNDERmachines and ARBURG peripher-als. Also, internal training pro-grammes are given, and it is notjust customers who are gratefulfor useful tips regarding machinetechnology and handling.

The demonstration hall livesup to its name. The latest genera-tion of ARBURG machines isinstalled here. It provides agolden opportunity for potentialcustomers to try out in practicaloperation ideas that will later

make their production easier.Special configurations with dedi-cated peripherals can be seen inaction to give an exact practicalpicture of how production willwork for them.

Machine acceptanceThis group is closely linked to

the engineering department, andis primarily concerned with cus-tomer-related acceptance of ma-chines in Loßburg. Purchasing andoptimisation of an ALLROUNDERmachine are thus accompanied byspecialist training, as in manycases it is not only a question ofmachines but also interactionwith a new mould, for example,which need to be tried and testedfirst.

AdviceCustomers can make the most

of applications technology know-how right from the planningstage. This aid is particularly ap-preciated as it avoids unnecessaryexpense for cost-intensive sectorssuch as tool technology, moulddesign, machine layout, capacitycalculations or handling tech-niques.

Here, applications such as process-ing two or three component, in-terval and sandwich injectionmoulding, insert/loading technol-ogy and silicon processing, arejust some of the many areas inwhich ARBURG AT can give itscustomers the right advice.

An informationsource forinjection mouldingAn integrated team withdecades of experience andsound knowhow. A synonymfor fast, efficient problemsolving, plus constant im-provements.

Only professionals deserve thisdescription. And at ARBURG theemphasis is on optimum use of allARBURG products by customers,right from the outset. What weare talking about is ARBURG ap-plications technology, or AT. Interms of hierarchy, this comesunder the company managementsector of marketing, also provid-ing sales support.

As is logical, employees largelyfocus on measures to ensure thatproduction runs smoothly fromthe outset at the customer’spremises.

Applications technology as asales support department entailsbringing the specialists workingthere and their knowledge to-gether with the customers andtheir requirements. The result is alively exchange between bothgroups, and close contact withcustomers.

AT operates separately in fourtask-related sub-groups: applica-tions technology, injection mould-ing, machine acceptance and ap-plications advice. In view of thedifferent requirements thesegroups specialise either in spe-cific customer requirements ormarkets in which ARBURG is ac-tive.

Engineering department anddemonstration hall

The engineering department,which is also attached to thedemonstration hall at the headoffices in Loßburg, has two tasks,namely one external or customer-

Cooperation ideally starts withthe initial planning, and thencontinues through mould and in-jection part design through tocommissioning of the entireinstallation designed to meet aparticular application, as well asdirect further technical help withthe production process.

Development of applicationstechnology

What now lies in the future willtomorrow be state of the art. Andas ARBURG has promised in itscompany charter to constantly bea pioneer in technical innovation,it is only logical that applicationstechnology should also play a rolein development matters.

The AT development group,which in the hierarchy comes un-der the development department,is involved in identifying trends inthe injection moulding market. Itsstaff develop and prepare newmethods and techniques on thisbasis for practical application.Their brief also includes constantimprovement of existing applica-tions and technological machineequipment, however. The applica-tions engineers thus ensure thatthe company, and consequentlythe customer, stays ahead intechnology, which is essential toboth of them to stay ahead of thecompetition.

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Jörg Gaiser, an AT expert at work

(Continued on page 10)

�QA R B U R G q u a l i t y

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ComprehensivechecksWith ISO certification, qual-ity control down to the lastdetail, responsible personnel,and compliance with themost stringent quality speci-fications, ensuring the re-quired production level hasnow become one of the keyfactors and an importantcriterion for companies todistinguish themselves fromthe competition.

But how does this work out inpractical terms? Who workswhere and how to achieve overallquality in a company? ARBURGworks every day towards reachingexpectations in this area. To seehow this works, we can look at anexample that is representative ofARBURG’s quality control effortsas one of the leading injectionmoulding machine manufactur-ers.

The component whose “qualitybackground” we propose to lookat in more detail in this report is acast iron blank, which will laterbe used as a fixed tool plate in anALLROUNDER C machine with520 mm tie bar spacing. It will beevident from this part that appro-priate quality control starts a long

way before its arrival at the gateof the works where this compo-nent will later be processed.

Series preparationThe first step in the manufac-

ture of a perfect cast part is de-sign discussions between thefoundry, the mould manufacturerand ARBURG. Solidification simu-lations carried out by the foundryhelp to identify the optimum partdesign for the specified use. Ini-tial testpieces are produced at thefoundry, when optimisation ofboth the item and the castingmethod may take place.

Then an initial sample deliveryof blanks will be approved for thefoundry. Assessment of theseparts is handled by ARBURG. Thedimensional stability of the blankis then checked by measuring itwith a 3D measuring instrument.

This is followed by ultrasound in-spection, identification of possi-ble material defects in the partand hardness tests, which deter-mines whether the componentwill ensure smooth processing.

Finally, the processability ofthe part is checked by wear moni-toring introduction as well.Points which need to be clarifiedin this are whether the structure(strength and toughness proper-ties) will ensure good process-ability.

Continuous monitoringComponents checked in this

way may be approved for massproduction. But even then impor-tant details have to be constantlymonitored in order to ensureoverall quality. The foundryensures uniform top quality pro-duction of blanks, for example,by cast analysis. For corrosionprotection, delivery is made withspecial tarpaulins which alsohelp to prevent damage intransit. On arrival, the castblanks undergo a goods-inwardcheck, recording any damagewith photographs of samples.The components are then plastic-coated with the ARBURG mint-green colour.

In the processing centres, theparts are prepared individuallyfor use, i.e. milled, drilled andthread-cut. Here the centresimplement fully automated moni-toring of the individual produc-tion stages based on program-ming specifications with simulta-neous measurement. If set valuesand actual values differ beyondthe permitted limits, the ma-chines are readjusted by the“Renishaw correction” system.

The first part produced for anorder is fully checked again on a3D measuring machine fordimensional stability. Furthersamples taken during the courseof processing ensure that produc-tion continues without defects.

International supportExperience, knowhow and

practical support are not justavailable to ARBURG’s Germancustomers, but to those world-wide as well, wherever it is re-quired. This is the responsibility ofthe “International Technical Sup-port” team, a marketing depart-ment which also works in closecontact with ARBURG Applica-tions Technology. Support is thusquickly at hand in conjunctionwith trading partners andbranches worldwide, whether it isfor cartridge production in SouthAmerica, sealing techniques inAfrica, silicon applications in Ja-pan or rubber processing in Scan-dinavia.

In the lead, at home andworldwide

To see just how good the serviceprovided by the ARBURG Applica-tions Technology and Interna-tional Technical Support teams is,you have only to visit one of themany fairs attended by more than40 experienced personnel fromthese departments.

Here you will always have timefor a personal chat to quickly es-tablish the crux of the matter andproblem areas. Generally poten-tial solutions can be offered evenat this stage, as well as questionsanswered and concrete solutionssought. AT and ITS are thusARBURG’s sources for providingdetailed knowledge about the in-jection moulding process.

So, how can we help you?

�QPersonnel self-testA further essential monitoring

aspect is the self-test for person-nel which has been part of work-ing life at ARBURG for severalyears now. This concept is basedon the individual responsibility ofpersonnel for the componentsthey themselves produce. For this,the processed cast parts arechecked again on site for compli-ance with the various specifiedtolerance values, as is the casewith threads. This self-test endswith the application of a personalidentification mark on the castpart before storage.

Problems can arise at any time.This does not, however, have thesame effect on sorting. For theparts we have been discussingthis generally means cavities,mould faults, surface defects suchas a coarse structure or dents andstructure problems, for exampledue to excessively hard, soft orbadly processed cast parts.

This can be remedied by struc-ture inspections by metallography,i.e. by producing “polished sec-tions”, and spectrum analysis todetermine the chemical composi-tion of the material.

Hardness tests using the shearing pinmethod in production control

ARBURG leaves nothing to chance:ultrasound inspection to identify inter-nal faults

QIS

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ISO

900

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Overallcertification

As the internationally recog-nised code of practice, ISO certifi-cation shows the customer whatquality standards the companyapplies to offer products andservices to meet competitionworldwide. At ARBURG, this doesnot only cover products and serv-ices, but also the environment.This is why the company has hadDIN EN ISO 9001 certificationsince 1995 and also ISO 14001certification since July 1998.

This creates synergy betweenthe two systems, which can beused accordingly to ensure thatthe company can offer optimumservices that are also environ-mentally friendly. Managementensures that specific companyaims are pursued continuously inboth areas. There is a common“ongoing improvement process”,

with the involvement of all per-sonnel and suppliers. Both ISOprocedures also require writtendocumentation of processes.ARBURG has developed its “Man-agement manual for quality andthe environment” to this end.

Internal audits enable a checkto be made on whether actualpractice reflects the theory. TheISO process is also a key factor forARBURG in this respect; manage-ment looks into this matter atregular intervals, so that any de-viations in set and actual valuescan be remedied promptly.

Finally, in addition to the in-ternal audits, there are also exter-nal inspections, conducted byoutside consultancy organisations.For combined certification, qualityand environmental managementare checked together.

TroubleshootingThe mechanism for handling

complaints – again an importantpart of ARBURG’s overall qualityassurance – is just as clearlystructured as controls and tests.The Purchasing and Quality Con-trol departments in the companywork in conjunction with the sup-plier on troubleshooting. This isnot based on allocation of blame,but focuses on remedying criticalpoints.

Complaints statistics enable acomparison to be made betweenindividual suppliers and helpARBURG realise the aim stated inits charter of achieving the bestpossible quality in its day to dayoperations.

In point of fact, these wide-reaching efforts to ensure a highquality level in terms of both costand time spent are by no meansinconsiderable. But the same ap-plies in this sector too: anythingthat can be avoided by preventivemeasures must by definition costfar less than repairing productsand the company image after theevent. This is why ARBURG willcontinue along this path in the fu-ture.

A R B U R G t e c h n o l o g y

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The ARBURG preform systemThe areas of application for

the ARBURG preform system pri-marily include the production ofsmall runs in the soft drinks sec-tor and for pharmaceuticals,medicines and cosmetics.

A vertical ALLROUNDER 420 C1000-350 forms the basis for aspecific application. To ensureoptimum injection moulding re-sults in the manufacture of pre-forms for PET bottles, thisALLROUNDER of special struc-tural design offers the ideal solu-tion. The vertical machine has asealing unit operating top down,which is particularly suitable forautomated solutions.

There is a 16-unit hot runnermould in the machine for theproduction of more than92,000 tubes or bottles per daywith a shot weight of 8.5 grams.

ProductionThe “electromechanical dos-

ing” system design enables si-multaneous tool mould move-ments, with dosage continuinguntil the next injection. Duringthe opening process, the injectionmoulded parts remain on themould core, i.e. on the top half ofthe mould. The removal platemoves horizontally into positionin the mould, the stripper platepushes the preform upwards frombelow from the core and presentsit with positive interlocking onthe removal plate.

After leaving the mould area,the injection unit advances andthe new injection cycle starts. Thepreforms are then moved by ahandling conveyor for furthercooling either by air or water andthen placed in a finished part con-tainer.

A convincing argumentIn this configuration, the 16

notches are in the bottom part ofthe mould. This means that thecavities are filled from the bottomupwards, ensuring optimum partsquality. Vertical mould removal

Bottlesmade easyThe market for PET bottles isgrowing: from the 61 billionmade in 1995, the number islikely to double to 123 bil-lion by the year 2000.

It is soft drinks in particularthat are primarily bottled in PETbottles (recyclable disposable orreusable bottles). Soft drinks andwater are the front-runners. Theadvantages of PET packagingcompared to glass bottles areself-evident; they offer the samestandard of hygiene but arelighter and therefore easier andmore profitable to transport. Themanufacture of raw materials andbottles and recycling require less

energy, and plastic bottles aremore stable than their glass coun-terparts. This was reason enoughfor ARBURG to launch into thismarket with an ALLROUNDER formaking PET preforms.

A run on PETIn Germany, the PET bottle is

gradually starting to appear. CocaCola was one of the first manu-facturers in the soft drinks sectorto use PET bottles on a widescale. The GDB (GenossenschaftDeutscher Brunnen) is conductingtests with PET reusable packag-ing. Soft drinks have been avail-able for some time, and mineralwater in PET bottles should soon

follow. Various major spring wa-ter suppliers such as Gerolsteinerhave in the meantime developedtheir own PET reusable bottlesand have already started market-ing them.

Cosmetics, medicines, andbeer

Due to the low cost of raw materi-als for polyethylene, a great dealof packaging has changed to PET.Examples of this can be found inthe cosmetics and pharmaceuti-cals sectors in particular.

But breweries have also re-cently been discussing bottlingbeers in PET bottles. Individualtests are already being run. In or-der to be able to keep the beerlong enough in plastic bottles,“barrier materials” can be added.

13

How bottles are madefrom preforms

After manufacture, the pre-forms are fed to a blower ma-chine. Here, infra-red radiantheaters heat up the preforms.The hot-profiled preforms arestretched in the blowing mouldsby means of an axially orientatedstretcher mandrel. Moulding ofthe bottles is completed by intro-ducing compressed air into thecavity at up to 40 bar. This proc-ess gives the bottle or tube itsfinal shape.

Complete ARBURG solutionWith this vertical machine,

ARBURG offers a complete spe-cialist system including a strippingrobot, preform injection mouldingtool, drier and if required a cool-ing unit in one go. It goes withoutsaying that we offer a specialist,comprehensive service from indi-vidual planning through to sup-port during on-line production.

T e c h T a l k

cally suggests an insert positiondetermined by plausibility calcu-lations. Simultaneous movementscan be programmed as easily asserial movements. The controlsystem identifies any missing ma-chine functions for insertion at asuitable position.

Another outstanding featureof the SELOGICA control system isits high integration capability. Forexample, the ARBURG 3 axis NCcontrolled system can be incorpo-rated completely in the controlenvironment and programmedwith the same operating system.

Independently of and simulta-neously with the injection mould-ing cycle, the SELOGICA cancontrol downstream peripheralssuch as stamping or assemblydevices. These units are startedindependently by an optional ma-chine function.

Multi-component machinesare frequently set up for highlyspecialised injection mouldingtools. The cycle is determined bythe manufacturer in a fixed pro-gram. This means that only a fewtools can produce on a machine,and for changes in the cycle themachine manufacturer has tomodify the fixed program at greatcost.

With the introduction of theSELOGICA control system, this isnow a thing of the past. Virtuallyall the usual market requirementscan be programmed directly bythe machine installer on site withthe standard software. Fixed pro-grams are no longer necessary.This not only saves time but alsocuts costs. All machine settingsincluding operating techniquesare saved on floppy disk. Thismeans that the use of different

So you want to use differentmoulds on multi-componentmachines? Or different spe-cialist processes, such assandwich, interval or combi-nation injection moulding onone machine? Or incorporatecomplex tool functions inthe machine process andalso still process inserts andfinished parts?

You can do all of these with-out any problem with theSELOGICA control on our S and Cseries multi-component machines.

Forget the usual fixed pro-grammes with specialist ma-chines! You can program anycomplex machine cycles in theusual SELOGICA way, with anoverview and an easy editing fa-cility.

The core of the SELOGICA con-trol is the process editor. Withthis, the machine cycle isprogrammed graphically withsymbols. The flowchart is alwayseasy to understand and offers acomplete overview. With applica-tions in the multi-componentsector the machine cycle can of-ten be highly complicated withseveral injection units and expen-sive mould technology.

The machine installer quicklyloses his overview, with conse-quent errors or unfavourableprocess settings. Not so withSELOGICA! Each individual ma-chine function is freely program-mable within the machine proc-ess. The control system automati-

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SELOGICA formulti-componentmachines

by the stripper platecan proceed withoutdeformation evenat relatively hightemperatures. Fur-ther cooling of theparts takes placeoutside the mould,which means shortercycle times – about4 shots/min in ourexample.

Stripping can beachieved relativelyeasily and thus morecost-effectively withthe design of the in-stallation. The footprintof the production unit can be re-duced to the minimum. Electro-mechanical dosing not onlymeans shorter cycle times, butalso more cost-effective materialprocessing with the same highdosage performance and energysavings.

Mould wear is minimised withthe vertical arrangement. Slidingcores do not have to travel as faras with horizontal systems. Thismeans that it is easier to changeto higher threads.

co-

T e c h T a l k

14

types of tool or different proc-esses on one machine are nolonger the exception but the rule.

With a rough definition of themachine cycle, this now has to beoptimised. Major savings can bemade in cycle time here too.There is no reason why differentfunctions which were previouslyhandled in serial form cannot becontrolled in parallel. Core pullersstarted in serial mode can beprogrammed simultaneously asmachine movements and starteddepending on the sequence.

In view of the often highly ex-pensive injection moulding toolsfor multi-component processing,the monitoring possibilities of thecontrol system are an importantfeature.

The SELOGICA system offers awide range of freely programma-ble monitoring features for this.Mould position monitoring is animportant aspect of this. Activa-tion of processes in which theposition of the mould needs to bemonitored (e.g. mould open untilintermediate stop) is handledsimply by marking it in the pro-duction process. The mould posi-tion can be monitored as often asrequired during a cycle.

Another particularly importantfeature is flexible programming ofmonitoring, if for example corepullers are controlled simultane-ously for other movements. Colli-sions in the mould obviously haveto be avoided in this. The processcan be monitored to check thatcore pullers operated for mould,ejector or injection movementshave reached their end positionbefore the reference axis hasreached a previously determinedpath position.

If injection moulds with sev-eral cavities are used, deformingof all moulded parts must beensured to prevent damage to themould when resealed. Optimisedmonitoring with infra-red orphoto-electric cell systems orvisual monitoring by means of acamera can also be incorporatedin the SELOGICA control systemto handle this.

The SELOGICA control systemproves its worth with the follow-ing features:

■ Graphic cycle programming■ Overview of machine cycle in

the form of a flowchart■ Freely programmable process

handling■ Virtually all the usual market

requirements can be met withthe standard software

■ Simple programming facility,especially of simultaneousoperation of functions

■ Simple editing in the currentcycle, ensured by plausibilitychecks

■ A wide range of monitoringoptions ensures perfect opera-tion

■ Special mould functions canbe incorporated in the cycleby programmable inputs andoutputs.

■ Peripherals including operat-ing techniques are fully inte-grated.

The line of approach soon be-came clear: training measuresshould improve the individual re-sponsibility of each employee,thus improving quality and pro-ductivity and achieving better jobidentification through motivation.

So what does teamworkmean?

Teamwork is firstly character-ised by clarifying the hierarchicalstructure. Members of the teamare in fact on equal footing, and ateam spokesman represents theviews of the team to the teammanager, who in turn is thecontact with the departmental orsector manager.

In the event of problemswithin the team, internal mecha-nisms are used first to solve prob-lems, instructed in training. Onlyif this way fails does the teamspokesman in his role as modera-tor look to the team manager, inorder to resolve the problemtogether with him and the teamby discussion. If a satisfactoryresult cannot be achieved in thisway, the matter can generallyonly be referred up the hierarchy.This solution has in practice beenused very rarely indeed withinARBURG.

The flat hierarchy is also no-ticeable in the work distributionwithin the teams. In simple terms,each employee has to be able tomaster and carry out all the taskswithin his team, in other words bean allrounder. This ensures thatthe overall work load can be com-pleted as flexibly as possible. Thisfactor is particularly important forsituations of absence due to ill-ness or leave.

Team Allround:new working methods

The successful introductionof new models into theworkplace can only be suc-cessful if there is somethingin it for everyone! Thismeans more flexibility andmotivation for the personnelinvolved and productivityand cost cutting for the com-pany. The key word thatbrings them together isteamwork: after 2 years’practical experience, we cannow report back.

As far back as Autumn 1995 itwas decided to introduce specialworkshops on the subject of intro-ducing teamwork at ARBURG.The project was named “TeamAllround”, as it was designed toincrease efficiency and qualityamongst other things by an all-out attack on employee qualifica-tion.

Before practical implementationof the project, there was a plan-ning phase lasting several months,focusing on a general decision asto the suitability of the changesto replace the former productionprocesses and structures effi-ciently.

AimsOther important aims included

reducing the machine throughputtimes by 20 percent, a furtherincrease in production quality, areduction in friction with othergroups and departments in thecompany and individual responsi-bility for identifying and remedy-ing weak points in production.The last point alone clearly showsthat reinforcing the individualresponsibility of each employee orhis group is of central impor-tance.

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A R B U R G o r g a n i s a t i o n

The high degree of flexibility ofthe new organisational structuremeans that working and free timecan be arranged relatively inde-pendently within the team itself.

All the above factors togethercontribute to personnel develop-ing a greater feeling of personalresponsibility, which meansgreater motivation in theworkplace.

Practical testsAfter just over 2 years of inten-

sive practical tests with the newworking arrangement now ex-tended to several teams, all thoseinvolved are satisfied. Collabo-ration between teams, teamspokesmen, team managers andhigher hierarchical levels has pro-ceeded smoothly, achieving pro-duction and quality targets.

Training by external trainingstaff has enabled personnel to as-sume responsibility for planningpersonnel and leave, working pro-cedures and internal team discus-sions. In return, senior personnel

have willingly ceded their powers,thus giving more room for deci-sion-making by the teams.

Pilot project with four teamsIn the first stage, four teams

were set up in the assembly sec-tor, to obtain practical experiencein a pilot project on teamwork.Assessment of the results wouldthen form the basis for a decisionfor or against teamwork. Person-nel in these teams were not onlytrained, however. Visits weremade to other firms already oper-ating a teamwork scheme, andthese served to illustrate to theteam members the specific ad-vantages and problems associ-ated with the new workingmethod.

In November 1998, an initialreport from the team leaders waspresented, and this proved verypositive. The introduction ofteamwork was accompanied byparallel changes in planning andselective machine approval, im-plemented retrospectively. Em-ployees also expressed their satis-

faction with the results, whichagain served to reinforce theteamwork concept. Individualresponsibility and motivationwere greatly increased, improvinginterdepartmental understandingand appreciation of problems bygreater communication betweenteams.

The commercial targets soughtwere achieved, and productionquality improved further still. Thismade it clear that teamworkshould not only remain a fixed el-ement of ARBURG’s companypolicy, but should be extended toother areas of the company.

In the interim this workingmodel has been introduced in allthe assembly sectors, electrical

production and electrical assem-bly. In the handling department ithas involved restructuring of theentire department. At the begin-ning of the year, the materialsmanagement sector was also in-cluded in the teamwork schemewith 60 employees. This meantthat an additional interface couldbe introduced for smooth han-dling of machine throughput inthe new working system.

A democratic structureIntroduction of the new work-

ing model focused on the person-nel and functional responsibilitiesin a team arrangement. Increasedindividual responsibility and moreflexibility in organising workingprocedures, and thus division offree time and leave, were consid-ered positive by all. Greater con-tact within and between teamsmeant that problem areas in theproduction process could be iden-tified and remedied.

Motivation of personnel finallyhas been improved by the factthat success in production withthe new working method is meas-urable.

Great satisfactionThere is satisfaction in all ar-

eas with what has been achievedso far. The emphasis here is on“so far”, as further steps towardsteamwork are planned for thefuture. In areas of the companywhere this tool can be used toimprove efficiency and motiva-tion, ARBURG will introduce it.Innovation does not only meancreating new products but alsolooking to achieve optimum effi-ciency and the best working envi-ronment in internal procedures.

A R B U R G s u b s i d i a r i e s

16

Constant expansionWhat started in 1992 with 1 (!)

employee, is now a completebranch structure by ARBURGstandards with eight employees.Management of the branch liesin the capable hands of Dr.Slawomir Sniady.

After the recent extensions,the building has an area of some250 m2. In addition to officesthere is a showroom with spacefor up to three ALLROUNDERmachines and an excellent or-ganised spare parts store to pro-vide a swift service in the eventof any problems.

This means that our Polishbranch is equipped as well and isas flexible as all our othersworldwide. This is in line with theARBURG philosophy, to offer notonly top quality machine technol-ogy in all the main regions butalso provide services for these.

A bridgeto EasternEurope

.. Polska .. .

At the beginningof the Nineties,Poland was, as

you might say, a test casefor ARBURG’s first steps intothe Eastern European “tar-get markets”.

The company is now representedin Poland, the Czech Republicand Hungary with its ownbranches. Target markets arecountries in central easternEurope, even if those keen ontheir development have presumedan easier time with introduction.At ARBURG, the approach hasbeen quite realistic. Our commit-ment to Eastern Europe is seenstrategically as medium to long-term measures. Planning is thusbased not on quick gains but asolid, partnership-based businessarrangement.

The branch in Poland was setup back in 1992. It is located inMichalowice near Warsaw about15 km from the international air-port. The aim was to take a posi-tive approach from the outset tothe continuing economic devel-opment forecast for the comingyears and contribute to the localmarket. As things stand atpresent, expectations have beenmet with regard to increased de-mand for high quality investmentgoods. The used machine marketwhich offered very favourableprices at the outset has graduallyfallen - largely due to improvedfinancing facilities- in favour ofnew machines.

Most Polish customers arestill very price-aware. Almost70% of ARBURG customers inPoland are first-time buyers, butfavourable terms of payment oralternative forms of financing arequite often part of the sales ne-gotiations.

Securing attractivelong-term market shares

Due to ARBURG’s long-termcommitment in Poland, the com-pany has been able to secure anattractive market share with itsefforts. The major part of ourclientele comes from the packag-ing and electrical industries.Gradually, however, we are start-ing to see major internationalautomotive companies who aretrying to become established inPoland, especially the Germanand Japanese, asking increas-ingly for injection moulding ma-chines.

As with all our other branchesworldwide, ARBURG Polska seesitself as a partner of plasticsprocessors, whom we can offer– continuing technical and

applications advice– training for operators and

engineers– fast spare parts resupplies

from a company warehouse– qualified service support– machine demonstrations in a

local showroom– mould testsdirectly on site.