Mold inventory management: it is reasonable to prepare several sets

Mold inventory management: it is reasonable to prepare several sets
Mold inventory is divided into three categories: in use, spare, and under repair. The spare ratio is usually 10% -20%, and for wheel types, it can be reduced to 5% -10%.
Classification of three types of inventory
In use mold: a mold currently in use on the production line.
Spare mold: a second or third set of the same wheel type, used for mold replacement or fault replacement.
Mold repair: A mold that is currently being repaired, modified, or awaiting inspection.
Separate statistics of the three categories are necessary to see the true production capacity and capital occupation.
How to determine the reserve ratio
Single large batch wheel type, with a backup ratio of up to 20%. One set of faults, the other set can withstand them.
For enterprises with multiple wheel types and small single product quantities, the reserve ratio can be reduced to 5% -10%. Every item is prepared, but it takes up too much capital.
The lifespan of spare molds will also naturally age. If not used for a long time, the coating and sealing components will degrade.
Calculation of turnover rate
The turnover rate of molds is equal to the annual output divided by the total number of molds. A low turnover rate indicates that the mold is idle.
A high turnover rate indicates that the mold is overloaded and maintenance risks are increasing.
There is no unified standard in the industry, and it needs to be judged based on the number of wheel types and order structure.
Storage and Maintenance
Molds should be stored in a dry and ventilated warehouse, avoiding outdoor stacking.
Apply anti rust oil to the cavity and drain the water circuit. Check the status once every quarter.
Xinfeng Mold will provide storage recommendations for wheel hub molds upon delivery, including rust prevention cycles and inspection items.
ledger management
Establish a ledger for each set of molds: number, wheel type, production date, cumulative mold times, maintenance records, and storage location.
Modular data is the basis for determining lifespan and arranging maintenance. Without a ledger, maintenance can only rely on intuition.
It is recommended to digitize the ledger and integrate it with the production system to automatically accumulate module times.
Disposal of idle molds
Long term idle molds can be considered for transfer, modification, or scrapping.
When the cost of renovation is less than 50% of the new mold, renovation is more cost-effective than purchasing a new one.
The reusable components (mold frame, guide column) of scrapped molds should be dismantled and stored as spare parts.
Calculation of safety stock
Safety stock is estimated based on replenishment cycle and consumption rate. The mold replenishment cycle is usually 45-70 days, during which the production demand is the lower limit of safety stock.
Enterprises with multiple wheel types can be managed according to ABC classification, with sufficient A wheel types and shared or outsourced C wheel types.
Linkage with production scheduling
Inventory data needs to be integrated with the production scheduling system. When scheduling production, the status of the molds can be seen, so as not to include the molds under repair in the plan.
Inventory frequency
Conduct a quarterly inventory check and reconcile the ledger with the physical items. When the difference exceeds 5%, the cause needs to be identified.
The mold ledger and the financial fixed asset ledger need to be reconciled regularly, and it is common for the two sides to have inconsistent statements.
The scrapping of molds requires approval, and unauthorized disposal may result in discrepancies between asset accounts and reality.
The storage location of molds needs to be updated in a timely manner, and the most common problem during inventory is that the molds cannot be found.
It is recommended to update the module data once a month for the ledger, as a delay of too long will lose its management significance.
Frequently Asked Questions
Q: How many spare molds are available?
Answer: Usually 10% -20%, and when there are multiple wheel shapes, it drops to 5% -10%.
Q: Will spare molds age?
Answer: Yes, long-term non use of coatings and seals will cause degradation.
Question: How is the turnover rate calculated?
Answer: Annual production divided by the total number of molds.
Question: How to store molds?
Answer: Dry and ventilated, apply anti rust oil, and drain the water circuit.
Question: What should be recorded in the ledger?
Answer: Number, wheel type, mold number, maintenance record, location.
Q: How to deal with idle molds?
Answer: Transfer, renovation, or disassembly for reuse.
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