Productive Innovation

The project “Innovation in micro-detail machining, development of solutions for grippers and checking fixtures for the automotive industry – implementation of the New plug-and-play injection mold concept” is an ambitious project of technological, marketing and organisational innovation and development.

It addresses leading-edge technologies that are still under development and are already in high demand from related industries. It also represents an important opportunity for Automoldes to grow and to gain visibility and recognition for its capacity and the quality of its services.

The manufacture of metal moulds for the production of technical injection-moulded plastic parts is a competitive sector with strong growth dynamics; its sustainable success is a testament to its capacity for innovation. Against this background, the company's strategy for developing this project focuses on completing 4 phases of activities:

Four phases of activities

1. Activity 1: organisational improvement of the company;
2. Activity 2: structural upgrading of existing processes;
3. Activity 3: innovation through the creation of new products and solutions for the market;
4. Activity 4: implementation of marketing strategies and promotion of services and products.

To this end, the initial aim is to implement organisational improvements in the company in terms of staff qualifications, the implementation of management and organisational software, and the creation of new working methods, always ensuring high quality standards.

Alongside the organisational improvements, the topics addressed by the project will be explored in detail, namely the machining and production of technical moulds for the production of vehicle lighting optics and the production and development of grippers and checking fixtures for plastic parts, their applications, operating principles, components and market, among others, through studies, training in new technologies, marketing plans and market strategies.

To develop and implement these new technologies, it is necessary to be able to develop complex mechanical components with a high degree of accuracy and precision, and to ensure their dimensional quality in terms of tolerances, clearances and shapes, among others.

The company therefore aims to innovate in the construction and development of more complex moulding surfaces, using new technologies and high-speed, high-precision machining equipment, in order to obtain high-quality surfaces with greater dimensional and geometric accuracy, in shorter lead times. This growth will make it possible to respond more effectively to increasing market pressures while remaining competitive. The forward-looking goal is to machine shapes of a few millimetres with nanometric precision.

Through the development of this project, the aim is to create a procedure for measuring and validating the metrological properties of the moulding surfaces, of the electrodes machined for subsequent EDM of the moulding surfaces, of the parts produced by the mould, and of the checking fixtures and grippers, carried out by qualified staff, thereby creating a system of dimensional and quality control of the work performed.

In mould production and development, creating the mould as a finished product of guaranteed quality is important to enable access to direct internationalisation. It is essential that the company is recognised as a quality supplier, in order to have a greater market impact and remain competitive. The aim is also to monitor the Quality Management System regularly to ensure compliance with the requirements and the sustainable and sound transition of the system to the new NP EN ISO 9001:2015 standard.

Disseminating the project's results, promoting the new technologies under development and demonstrating the company's scientific and technological capabilities are extremely important to increase demand in the domestic market and to enter the international market directly. To this end, the plan is to produce promotional material and to promote the company at national and international trade fairs.

Medium- and long-term objectives

• Increased production capacity, in terms of execution complexity and meeting delivery deadlines, through the acquisition of modern mould-making equipment, staff qualification and the overall organisation of the production process;
• Improved quality of final products by reducing defects and rework by around 80% relative to total production, through organisational improvement and the early identification of the vast majority of the defects currently found in the moulds produced, with greater organisation, mechanisation and monitoring of the entire production process;
• Starting the production of technical moulds for vehicle lighting optics – a leading-edge technology that requires knowledge of LED light transmission through plastic material and the ability to machine prisms efficiently in the moulding areas – and of gripper and checking fixture solutions that allow the mould to go directly into automated series production, attracting more customers and reinforcing the commitment of existing customers through the offer of complete solutions;
• Achieving direct international turnover of approximately 30% in the year after the project, through the adoption of the “New plug-and-play injection mold” concept;
• Replacing services subcontracted throughout the production process with in-house capabilities, which, in addition to improving the quality of the services provided, represents a tangible commercial gain and opens up a new line of business by providing services to third parties.

To develop this project, the company will use all its technical and technological capabilities, from its engineering and design knowledge and experience to its equipment and employees, investing in specific and ongoing training.

Through this project, Automoldes will invest in new production processes, with the manufacture of new products, as well as in strengthening its organisational and production methods, which become even more relevant given the sector in which the company operates.

At the current technological level, much of the production that Automoldes intends to carry out is not possible, which has been a considerable constraint on the company's growth. Moreover, the new technologies to be implemented will underpin and support the company's direct internationalisation, as it seeks to enter stronger and more competitive markets. To this end, Automoldes needs to strengthen its production capabilities, increase the quality of its products, reduce response times and manage raw materials and resources such as energy more efficiently.

Innovation will be felt at every level, with innovative investments in a market segment with potential and significant improvements in productivity, product quality, lead times and energy costs, among others. By introducing new equipment, and backing this investment with a stronger organisational structure, Automoldes will be able to respond more effectively and promptly to all market demands, with a view to its internationalisation.

The company is dedicated to the design, development, production and maintenance of plastic injection moulds. It is located in the municipality of Trofa, and the project will be developed and implemented at its premises.

In view of the above, and taking into account the pursuit of the initiatives proposed in the application, it is concluded that the investments constitute process, product, organisational and marketing innovations of an incremental nature at national and international level.