Mold Design

Mold design refers to a digital design of a mold. As the initial phase in the Injection Mold Engineering (IME) system, it ensures that the requested design has been carefully assessed before the CNC operators create the mold.

Mold Design Flow Chart

The mold design process starts when the mechanical engineer (ME) creates a record in the Mold Design table with the help of the mold engineers. Once created, ME attaches 2D/3D drawings to the Attachment table and specifies the mold design’s verifier and approvers in the Mold Design Revision History table. Upon submission, TIGA will keep all stakeholders updated by sending notification emails. Once the record is Approved, the mold engineers will continue the mold design process by preparing the mold design’s failure mode and effect analysis (DFMEA), 2D, and bill of material (BoM).

Please check the Status column to monitor the progress of the mold design.

Mold Design Status

Status Name	Description
Open	It is the status of a newly created record.
Design 3D Process	The Mold Design Revision History status is Approved, meaning all approvers approve the submitted record.
Begin DFMEA	The mold engineers link the Design Molding Revision History to the DFMEA table.
Closed	The mold engineers manually update the Mold Design record status when the mold design process finishes.

Creating a Mold Design

To create a mold design request:

Create a new record in the Mold Design table.
Complete the mandatory fields (shown by *) in the

Mold Design Request/FRM-14-001-007 and Product Specification/FRM-14-001-006 sections.

Upon the request creation, TIGA will send a notification email to the Formulatrix project’s mailing list and update the record status to Open.

Create New Mold Design Window

Below are the fields in the Create New Mold Design window and their descriptions.

Mold Design Request/FRM-14-001-007

Field Name	Description
Division*	Requester’s Name and Formulatrax ID.
Project*	Product type.
Status	A field to define the record’s status. If you leave it empty, it will be set to Open.
Mold Design Type	Mold design purpose (Engineering or Production). Choosing Engineering requires you to complete either the Part Name or Part Number fields, while choosing Production requires you to complete both.
Priority*	Mold design urgency (Medium, Urgent, or Top Urgent).
Part Name	Requested part’s name filled by the requester. Consult the project’s PIC.
Part Number	Requested part’s number filled by the requester. Consult the project’s PIC.

Product Specification/FRM-14-001-006

Material Selection

Field Name	Description
Wear Temperature (Celcius)	Maximum temperature the material (plastic) can handle. Note The value will affect the material used to create the part, i.e., PP, ABS, etc.
Color	Part’s color as approved by the PM in FUSA.
Transparency	Transparency indicator. Select Yes if the part is transparent or No if it is not.
Chemical Resistance	List of chemicals harmful to the materials.
Product Tolerance	Expected dimensional variations (µ) of the product due to factors like temperature, machine, materials, etc.
Material	Type of engineering material, for example: acrylic, silicon, PFE, and others.
Shrinkage (in%)	Percentage of material compression/shrinkage listed in the material safety data sheet.

Injection Mold Engineer

Field Name	Description
Approver	IME Division Manager’s name.

Requester

Field Name	Description
Requester*	Requester’s name.
Requester Date*	Record creation date.

Visual

Field Name	Description
Flash Acceptance	Excess materials indicator. Check if excess materials exist.
Flash Acceptance Notes	Value (µ), characteristics, and Flash Acceptance position.
Warpage Tolerance	The maximum value (µ) of acceptable material bending.
Surface Finish	Surface texture types including Glossy, Texture, Mirror, Sand Blast, and Other.
Other Surface Notes )required if surface is other**	Additional information if selecting Other in the Surface Finish.

General Requirement

Field Name	Description
Stack Tolerance Note	Tolerance value (µ) of the item’s mechanical fit with other parts/components.
Assembly Tolerance Note	Tolerance value (µ) of the precision position between parts/components.
Thermal Expansion Notes	Acceptable value (µ) of matter changes because of the thermal.
Critical Point Note	Important information about the part quality.

Adding an Attachment

Attaching a 2D and 3D drawing in PDF or XT format is necessary to help the mold engineers further understand the request. Follow the standard attachment creation procedure.

Creating Mold Design Revision History

After adding attachments, create a record in the Mold Design Revision History table, and specify the verifier and approvers. ME only needs to complete the Attached Data section as TIGA automatically fetches the data in the FRM-14-001-007 section from the Mold Design table. The following are fields in the Attached Data section and their descriptions.

Field Name	Description
Attached Data	Type of attachment.
Finished Date Plan	Expected finish date of the mold design request.
Verified By	Project leader.
Approver 1	ME manager.
Approver 2	IME manager.
Approver 3	FUSA product manager.

Note

When the record is created, TIGA will set the Mold Design Revision History record to Draft.

Submitting Mold Design Revision History

Mold engineer reviews the Mold Design Request and Product Specification sections in the Mold Design table before submitting the Mold Design Revision History record.

Tip

Read editing records to add product specifications.

To submit mold design revision history:

Select a mold design record in the Mold Design table.
Open the Mold Design Revision History table on the Related Tables.

Note

Only a Draft Mold Design Revision History record can be submitted.
Select View Mold Design Revision History in the Actions button.

Mold Design Revision History Report Window
Select Submit in the Mold Design Revision History Report window.

Post Condition

TIGA will send a notification email to the verifier and approvers of a mold design request.

Tip

Check the status to track the progress of the Mold Design Revision History record.

Status Name	Description
Open	It is the status of a newly created record.
Submitted	This status shows that the record needs approval from approvers. TIGA will send a notification email to the approvers.
Approved	All approvers approve the Submitted record. TIGA will later send a notification email to the requester.
Revised	The Submitted record is not approved. Tiga will automatically create a Draft record for the requester. Revise the draft before submitting it for approval.

Approving or Rejecting Mold Design Revision History

Only “Injection” group members can approve or reject the mold design request.

To approve or reject a mold design request:

Access the mold design using one of the following options:

Click on the link in the Design Molding Revision History email.

Approve Mold Design Request Email

Go to the Mold Design Revision History table and select a record with Submitted status.

Select View Mold Design Revision History in the Actions button.

From the Mold Design Revision History Report window, select Approve to accept
or Revise to reject the record.

Post Condition:

The status of Mold Design Revision History record will turn into Approved, and the system will change the status of the Mold Design record to Design 3D Process after all approvers approve the Mold Design record. If any approver does not approve the request, the system will automatically change the status to Revise and create a new record with a Draft status. Revise and submit the newly created Draft record to submit the Mold Design record.

Approved Mold Design Revision History

Note

TIGA updates the Version field incrementally to show the design history.

Creating or Editing DFMEA and DFMEA Line Items

The design failure mode and effect analysis (DFMEA) mitigates the risk of failure. The mold engineers perform DFMEA to establish and then minimize the part’s Risk Priority Number (RPN). They will ensure that potential hazards are carefully assessed every time the DFMEA evaluation finishes and create a record in the DFMEA table and its line item after the Mold Design Revision History record is Approved. Tiga will change the Mold Design record status to Begin DFMEA when the DFMEA record is created.

Check the description of each field in the DFMEA and DFMEA Line Items window.

DFMEA

Field Name	Description
Product#	Part’s name as written in the Part Name field in the Mold Design window.
Process#	Process type. Enter “Injection Molding” for this field.
Revision#	Number of revisions made.
Core Team	Name of the project the part belongs to.
Process Responsibility	Name of the mold engineer involved in the mold design process..
Contact (email)	Process Responsibility personnel’s email address.
Site	Molding location. Currently, the molding site is only Formulatrix Salatiga (PSL).
FMEA Number	Number of Failure Mode and Effect Analysis (FMEA) meetings.
Prepared By	DFMEA record creator’s name.
FMEA Date (Original)	Scheduled FMEA meeting date.
FMEA Date	FMEA actual meeting date.
Mold Revision Document Number	Document number taken from the Mold Design Revision History table.

DFMEA Line Items

Field Name	Description
Potential Failure Mode	Possible vulnerabilities causing setbacks.
Potential Effects of Failure	Possible failure mode effect on customers.
SEV	Potential Effects of Failure score.
Potential Cause(s)/Failure Mechanisms	Cause of mold failures.
OCC	Potential Cause(s)/Failure Mechanisms frequency.
Detection	Possible solutions or measures to detect failures.
DET	Detection score.
RPN	Risk Priority Number calculated from SEV x OCC x DET.
Recommended Action(s)	Suggestions to minimize failure and improve the mold design.
Responsibility and Completion Date	PIC (mold engineer) of FMEA meeting implementation and expected completion date.
Action Results	Result after implementation (progress).
Action Taken	Preventive action taken based on potential failures.
Result SEV	SEV result after Action Results implementation.
Result OOC	OOC result after Action Results implementation.
Result DET	DET result after Action Results implementation.
Result RPN	RPN result after Action Results implementation.

Creating or Editing 2D, BoM, and BoM Line Items

Upon approval, the mold engineers will prepare the standardized 2D drawing and Bill of Materials (BoM) of the created mold design record. To do so, create a record in the BoM Mold Design table on the Related Tables. Then, add every component needed in the BoM Line Items. Finally, update the status of the Mold Design table to Closed to indicate mold design process completion.

Mold Design BoM

Field Name	Description
Document Number	Document call number (generated automatically by the system).
Mold Report Number	Report Number from Mold Design table.
Project	Formulatrix project.
Mold Name	Part Name from Mold Design table.
Release Date	Mold Design BoM release date.
Author	The mold engineer who creates the Mold Design BoM record.
Revision Number	Number of revisions made to a record. Tip Write “0” for a new record.

Mold Design BoM Line Items

Field Name	Description
Sub Assy	Name of a larger manufactured product the requested part belongs to. Complete this field only if the part is a unit assembled separately but designed to be incorporated with other units into a larger manufactured product.
Part Description	Part information.
Part Number (IME)	Created part call number if manufactured by Formulatrix.
Part Number (VENDOR)	Manufacturer or vendor number. Note No need to complete this field if the part has Part Number (IME).
Category	Part category (Assembly, OTS, or MTS part).
Quantity	Total number of the requested part.
Material	Material used for creating the part.
Raw (mm)	Part measurement. P: Panjang (length) L: Lebar (width) T: Tinggi (height) D: Diameter
Weight (kg)	Estimated weight of the mold design.
Vendor	Raw material vendor or suppliers’ name.
Assembly Part No	Number given by mold engineers indicating the mold as an assembly part.
Assembly Description	Assembling instructions based on Assembly Part No.
Author	Record creator’s name.