DENSO
Automotive
Sub-50 Second Fully Automated Mold Changes at DENSO
World's Fastest Automated Mold Change System
Challenge & Solution
The Challenge
- DENSO, a global leader in automotive climate control products, needed to dramatically reduce changeover times across multiple international facilities while maintaining the highest safety and quality standards. Manual processes were limiting flexibility and increasing labor costs.
The Solution
- EAS engineered and installed a complete Quick Mold Change (QMC) automation solution including magnetic clamping, automatic coupling systems, mold change tables, preheating stations, bridge tables, driving systems, monitoring systems, and integrated control interfaces.
Key Results
Measurable improvements achieved through our solutions
<50
Seconds
Fully automated mold change time
>95%
Machine Availability
Near-continuous production
100%
Automation
No manual intervention required
Global
Implementation
Standardized across facilities
Implementation Details
- Magnetic clamping systems for secure, rapid mold holding
- Automatic multi-coupling for utilities (water, hydraulics, electrical)
- Mold change tables for efficient transfer and staging
- Integrated preheating systems for mold temperature management
- Bridge tables and driving systems for automated mold movement
- Real-time monitoring systems for process control
- Operator walking platforms with safety interfaces
- Centralized control system integrated with machine controls
Solutions & Products Used
EAS Magnetic Clamping System
High-force magnetic clamps for 1300T machines
EAS Automatic Coupling System
Multi-utility quick connect solutions
EAS Mold Change Tables
Automated mold transfer and preheating stations
EAS Control & Monitoring System
Integrated automation control with safety features
Additional Benefits
- Drastically reduced inventory requirements
- Safer working environment with minimal manual handling
- Significant reduction in labor costs
- Consistent changeover quality and repeatability
- Clean, organized production environment
- Enables true just-in-time production