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Industrial Molds, based in Rockford, IL, has been building precision tooling domestically for over five decades. In 2005, the company recognized that staying competitive in high-mix, low-volume manufacturing required a new approach. Partnering with EROWA Technology (Arlington Heights, IL), Industrial Molds became an early adopter of automation technologies, integrating a complete Flexible Manufacturing Concept (FMC)-which entailed tooling, presetting, robots, and software-into its operations. Today, its shop floor stands as a benchmark for what automation in moldmaking can achieve.

Staying Ahead in a High-Mix, Low-Volume Environment

Moldmaking is inherently custom work. Each block of steel requires unique programs, unique set-ups, and a commitment to precision measured in microns. Traditionally, this made automation difficult.

By 2005, Industrial Molds faced a bottleneck in graphite cutting. Operators were running at maximum capacity, yet downtime between set-ups left machines sitting idle too often. The company needed to improve throughput without sacrificing precision.

Stepwise Integration of EROWA Technology

Industrial Molds began its automation journey with EROWA pallets in a single graphite cutting cell.

"In using the pallet system, we quickly realized the benefits of automation," said Kris Grey, Industrial's Production Manager.

The results were immediate: reduced errors, faster throughput, and improved consistency.

Zero-point tooling played a key role in this efficiency. Because the steel is positioned identically every time it is loaded onto any machine, and the pallet's built-in skew allows the machine to automatically find the center point, set-ups are faster and more precise-eliminating manual alignment and reducing mistakes. Mistakes that previously occurred were no longer possible.

From there, Industrial Molds expanded into its wire EDM department, and then milling, and most significantly, into quality via its CMM machines. This evolution led to a full-shop integration with EROWA's Job Management System (JMS 4.0 MoldLine) software.

Dan Pilolla, President of EROWA, stated, "Industrial Molds was an early adopter and embraces all four FMC segments: Tooling, Presetting, Robots, and Software. With EROWA's powerful JMS software, all operators work off the same platform, tying production together from start to finish."

Benefits of the FMC segments include:

• Tooling-Standardized pallets and holders reduce errors and set-up time.
• Presetting-Offline preparation ensures machines are cutting, not waiting.
• Robots-Cells now run lights-out, maximizing spindle utilization.
• Software (JMS)-Scheduling and data management orchestrate the entire shop floor from one platform.

The Results: Efficiency, Accuracy, Workforce Agility

The impact of automation at Industrial Molds has been measurable and profound.

As Grey explained, "Before automation, we had a team of six operators in our wire EDM department to run 11 EDM machines. With EROWA, Industrial Molds outputs more production with only two wire EDM machines and only one operator." In addition, the training time for a new hire is condensed. Grey explained: "Before EROWA, seven years of experience was required to work in our EDM department; now we can get a newer operator up and running in about two weeks."

Pilolla added: "With today's labor market, companies need to be as efficient as possible, which means maximizing machine up-time, including lights-out manufacturing."

Solving Bottlenecks While Maintaining Quality

At its core, Industrial Molds' automation journey has been about eliminating bottlenecks without compromising quality. EROWA Technology has enabled Industrial Molds to grow by solving production challenges while maintaining the highest levels of precision. This balance-efficiency with accuracy-is what differentiates Industrial Molds in the market and enables long-term competitiveness.

The Partnership: Why Industrial Molds Stands Out

"Industrial Molds' early adoption of our JMS system made them a cutting-edge moldmaker in the U.S. market, with software capable of managing an entire shop floor," said Brendan Perry, Sales Manager with EROWA.

"While many shops use EROWA products, not all embrace all four FMC pillars," noted Pilolla. "Even more unique is its use of JMS in a high-mix, low-volume environment."

Perry added: "Many shops-especially job shops-still today do not understand that automation is not exclusively for the realm of production manufacturing. Where most assume automation is not possible, Industrial Molds demonstrated that even with unique, day-to-day work, automation can be fully leveraged."

Pilolla said: "For Industrial Molds, automation is not just about machines-it is about competitiveness in a tight labor market. Having high-end moldmakers like Industrial Molds as a benchmark reinforces EROWA's principles to improve efficiency and throughput without any sacrifice in quality."

Davila reiterated: "Industrial Molds' visionary and forward-thinking ability has propelled them to the forefront of American manufacturing. Its journey with EROWA demonstrates what is possible when a moldmaker not only invests in automation, but embraces it across the entire value chain. Its early adoption, methodical integration, and commitment to continuous improvement have made them a pioneer in the industry.

For more information contact:

Industrial Molds

a Division of Pyramid Molding Group

5175 27th Ave.

Rockford, IL 61109

815-397-2971

customer.service@industrialmolds.com

EROWA Technology, Inc.

2535 S. Clearbrook Drive

Arlington Heights, IL 60005

847-290-0295

info@erowa.com