Mold Maintenance Analysis in Glass Industry. Step A.

Silvio Ruiu
Jan 4
2 min read

Updated: Jan 24

FAT: New process acceptance test on client's glass molds.

Overview.

In the glass industry, there is a fundamental hierarchy of assets that most managers overlook. Let’s be direct: If your I-S machine fails, which by billing cost is one of the most expensive assets you have, you can ship your molds to another plant and continue production.

But if your molds fail, no I-S machine in the world can replace them.

With the long lead-times, logistical challenges, and direct impact to the appearance and functionality of the final product, this unique and relatively inexpensive part will have the potential to compromise your relationship with your customers, forcing them to discuss again their supply chain contracts with you.

Restoring that relation and trust is usually expensive and seldom without consequences.

If you ask any experience glassmaker, you will be told that molds mold shops are the most offenders of molds’ lifecycle; in fact, much more offensive than the I-S machine and the glass making process.

The molds are your most critical asset.

Yet, they are often subjected to maintenance processes that treat them like scrap metal rather than a precision tool. If your cleaning method rolls the seams, you aren't "cleaning"—you are destroying your EBITDA, one cleaning cycle at a time.

Shifting the mindset, from maintenance operations to asset management.

Mold life can be summarized in this loop: Storage > Lubricant > IS machine > Cleaning > Eventual mold repair > Storage. Unless is going straight to be lubricated getting ready again fort the IS machine.

The Choice: 5 Methods under the LEAN Manufacturing Lens.

To protect these assets, we must evaluate technologies: eliminating waste (Muda) and ensuring process stability, possibly tend to quality and standardization.

Options available today are:

Manual Air Blasting.
Automated Air Blasting.
Wheel Blasting.
Ultrasonic & Chemical Baths.
Laser Cleaning.

All will be discussed and investigated from both sides: technical and economical to understand which one and in which case is performing better in terms of TCO and EBITDA impact.

Summary of the analysis:

Step A: molds as primary asset of a glassmaker. (this article)
Clarifying importance of molds for glassmakers. Target: all people involved in glass industry from mold shop to corporate management.
Step B: Molds impact on EBITDA.
How cleaning of the molds impact on the P&L of a glass plant. Target: plant Managers and corporate management.
Step C: Professional standard inside the mold shop.
Technologies available and Lean manufacturing analysis. Target: mold shop Managers and Supervisors, plant Managers.
Step D: financial analysis of the options available.
Summarizing all the results under Lean manufacturing. Target: plant and corporate management.