Manufacturing Processes

Procedure taken on latest Tools manufactured

Trojan Manufacturing

Procedure taken on latest Tools manufactured

Product manufacturing today requires innovative, controlled, lean manufacturing solutions that bring you high quality, reliability and a sustainable competitive advantage. How can you accomplish this when a competitive edge often requires unique solutions that can’t simply be obtained “off the shelf”? The answer lies in manufacturing processes.

One way to develop these is with the help of a company specialized in designing and developing custom manufacturing processes. At Trojan Manufacturing have the experts, the tools and the facilities to do just this. Our experts specialize in areas like process development, quality improvement in manufacturing, and improving productivity in manufacturing. Wherever your focus lies, if you need to realize custom manufacturing solutions in a lean manufacturing environment, we have the people and the experience you need to achieve this in accordance with your specific requirements.

We received an enquiry from the customer outlining the information required. Data received was in the form of an email with a powerpoint attached showing blow moulded ducts laid out i.e. Single impression, 1+1 and 1+1+1 impressions of the various ducts.
Then the Cad data supplied was imported into Visi using the Step importer.
Each part was copied onto a separate layer to keep the integrity of the original Data.
The procedure now is to determine if each part has been modelled in such a way to be capable of moulding without any undercuts and capable of having a split line generated all around the component.
Along with any feasibility issues regarding mouldability of each Duct a new slide is created in the existing powerpoint and each part is pasted into its relevant slide, now using labels we highlighted all the issues.

This powerpoint was then sent back to the customer who then proceeded to modify the parts to mould.
We then received a new Cad file to interrogate and make sure the parts are ok.
We now created a quote for each tool layout outlining the tool approx. size, cost and timing.
When the quote is accepted, we received an order which in turn changed the quote into a live job.
Now the next step was to create the lost heads and blow pins to suit the relevant moulding machines (This platen data for each machine the customer uses is kept in a directory for reference).

We then sent this file for each tool to the customer for approval (The layout must be capable of creating a finishing machine).
When the layout is approved, we continued to fully design the tool to fit the platens required i.e. adding split line joints – water circuits – location pins and bushes – bear traps – neck knives – vents – sealing and mounting plates – bolting patterns – risers to meet the minimum tool height as stated by the platen data – lifting frame to mount the tool onto the blow mould press.
When the tool design is complete this was sent to the customer for approval.
On receipt of the approval we continued to order the material. While waiting for the material we created the cutter paths for the Cnc machining.
Now a timing plan using Microsoft Project is created for the customer and the Cnc
machinists.

When the material is delivered to the relevant Cnc manufacturing company, previously approved by Trojan Manufacturing and ISO certified, machining commences as the timing plan outlines and is monitored by Trojan throughout the manufacture.
Machining operations complete at various stages the bedding out commences and benching the main form as required.
During the various stage’s inspection is carried out to compare the Cad data to actual finished surfaces.
Before we can start the assembly, we must mask around the form with protective tape ready to shotblast the form which allows the air to be removed in the blowing procedure.
After shotblasting we now Cnc engrave all the relevant Part numbers etc.

Now we can start assembling the tool halves i.e. Pin half and bush half.
When assembled the water circuits are pressure tested to make sure there is not any sign of leaks. This completed a label is attached to each circuit with the days date.
The lifting frame is now added which has been previously tested.
The tool can now be delivered to the customer by the machining company, on the behalf of Trojan accompanied with Trojan deliver notes.
This procedure to manufacture blow mould tools is to maximise our capability of never having a capacity problem because we have approved various companies all of which have ISO accreditation and are more than capable of Cnc machining our tools. They are choosing at the time based on capacity and machine sizes to suit the tools required at any given time.

Trojan Manufacturing

Procedure taken on latest Tools manufactured

We received an enquiry from the customer outlining the information required. Data received was in the form of an email with a powerpoint attached showing blow moulded ducts laid out i.e. Single impression, 1+1 and 1+1+1 impressions of the various ducts.
Then the Cad data supplied was imported into Visi using the Step importer.
Each part was copied onto a separate layer to keep the integrity of the original Data.
The procedure now is to determine if each part has been modelled in such a way to be capable of moulding without any undercuts and capable of having a split line generated all around the component.
Along with any feasibility issues regarding mouldability of each Duct a new slide is created in the existing powerpoint and each part is pasted into its relevant slide, now using labels we highlighted all the issues.

This powerpoint was then sent back to the customer who then proceeded to modify the parts to mould.
We then received a new Cad file to interrogate and make sure the parts are ok.
We now created a quote for each tool layout outlining the tool approx. size, cost and timing.
When the quote is accepted, we received an order which in turn changed the quote into a live job.
Now the next step was to create the lost heads and blow pins to suit the relevant moulding machines (This platen data for each machine the customer uses is kept in a directory for reference).

We then sent this file for each tool to the customer for approval (The layout must be capable of creating a finishing machine).
When the layout is approved, we continued to fully design the tool to fit the platens required i.e. adding split line joints – water circuits – location pins and bushes – bear traps – neck knives – vents – sealing and mounting plates – bolting patterns – risers to meet the minimum tool height as stated by the platen data – lifting frame to mount the tool onto the blow mould press.
When the tool design is complete this was sent to the customer for approval.
On receipt of the approval we continued to order the material. While waiting for the material we created the cutter paths for the Cnc machining.
Now a timing plan using Microsoft Project is created for the customer and the Cnc
machinists.

When the material is delivered to the relevant Cnc manufacturing company, previously approved by Trojan Manufacturing and ISO certified, machining commences as the timing plan outlines and is monitored by Trojan throughout the manufacture.
Machining operations complete at various stages the bedding out commences and benching the main form as required.
During the various stage’s inspection is carried out to compare the Cad data to actual finished surfaces.
Before we can start the assembly, we must mask around the form with protective tape ready to shotblast the form which allows the air to be removed in the blowing procedure.
After shotblasting we now Cnc engrave all the relevant Part numbers etc.

Now we can start assembling the tool halves i.e. Pin half and bush half.
When assembled the water circuits are pressure tested to make sure there is not any sign of leaks. This completed a label is attached to each circuit with the days date.
The lifting frame is now added which has been previously tested.
The tool can now be delivered to the customer by the machining company, on the behalf of Trojan accompanied with Trojan deliver notes.
This procedure to manufacture blow mould tools is to maximise our capability of never having a capacity problem because we have approved various companies all of which have ISO accreditation and are more than capable of Cnc machining our tools. They are choosing at the time based on capacity and machine sizes to suit the tools required at any given time.

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