At the 5th National Mold Making Summit organized by UKUB, the industry`s problems and proposed solutions were discussed. The summit, which also evaluated the mold industry`s future vision, attracted considerable interest from industry members.
The summit, organized by the National Mold Manufacturers Association (UKUB) at a hotel in the Automotive Subsidiaries Organized Industrial Zone (TOSB) in the Çayirova district of Kocaeli, addressed all aspects of the mold making industry. The summit, sponsored by Ses3000 / YCM, began at 9:45 a.m. on Thursday, October 1, 2015, and continued throughout the day. UKUB President Samil Özogul stated that the summit aimed to conduct a SWOT analysis of the Turkish mold making industry. Özogul emphasized that the contributions of all segments, from the main industry to the smallest suppliers, with their diverse perspectives, are crucial for the development of Turkish mold making.
Samil Özogul stated that the mold industry needs both technology and qualified personnel to use it, and stated that the main reasons for the problems faced by the Turkish mold industry are the inadequate utilization of technological innovations in many processes, from design to delivery, and the lack of qualified personnel. Özogul explained that this has made it impossible to achieve sustainable standards in pricing, quality, efficiency, and profitability, and that high costs and long lead times have reduced their competitiveness.
THE MOLD INDUSTRY IS SHRINKING RAPIDLY WORLDWIDE, BUT GROWING IN TURKEY
President Özogul pointed out that, according to official data from the American Employment Agency, despite the mold industry being one of the highest-paid occupations, employment in the sector has decreased by 45 percent and the number of operating companies has decreased by 36 percent in the last 10 years. Samil Özogul stated, “According to data from the same institution, 80 percent of mold manufacturers are seeking qualified personnel but are unable to find them.” He explained that the new generation is not choosing to work in this sector, which also requires intense physical labor. He stated that even with high wages, they are reluctant to demonstrate the patience required to learn a profession. Instead, they are opting for even higher value-added sectors such as aerospace, defense, IT, finance, and entertainment.
President Özogul explained that the Turkish mold industry, unlike many other developed countries, has grown by 250 percent in the last 10 years, and that its problems have increased along with the need for employment. He said, “We need both technology and the qualified people to use it. The lack of both should be considered the greatest threat to our industrial sectors, and measures must be taken immediately.” Özogul stated that many mold makers in Turkey still don`t even use systems like automatic tool change, tool pre-preparation, and quick clamping on CNC machines. He continued: "When these systems are used on a correctly selected machine, with the right tools and correctly developed CAM programs, it`s possible to increase machine efficiency by up to 50 percent. While the average annual operating time for a CNC machine used in the mold-making sector in developed countries is 6,000 hours, in Turkey it`s around 3,000 hours. Even in our best companies, this only amounts to 4,500-5,000 hours. What`s even sadder is that most of our companies aren`t even aware of this and turn to new machine investments as soon as the workload is short. At this stage, we use MDC, or manufacturing data collection systems, to first analyze existing We must make equipment efficiencies measurable and then carry out improvement work.”
MOLDING IS THE CORNERSTONE OF THE INDUSTRY
Speaking at the summit, Süheyl Baybali, General Coordinator of the Automotive Parts and Components Manufacturers Association (TAYSAD), emphasized that the molding sector is one of the cornerstones of industrialization. Emphasizing that molds are the most fundamental equipment for standardized, low-cost production, Baybali stated that the sector has undergone significant development in Turkey, particularly in the last 15 years, and that the molding sector is crucial for many sectors, particularly the automotive sector.
Süheyl Baybali emphasized that approximately 70 percent of molds produced globally are used in the automotive sector, noting that new investments in the automotive industry have increased the need for molds. He said, “The availability of lightweight materials is increasing, especially in the future of the automotive industry, and the mold industry must adapt to this. It is important to increase competence in new materials in the sector and, consequently, to eliminate software deficiencies and resulting errors. In the automotive industry, where processes are significantly shortened, production times in mold production must be reduced, efficient production methods must be used, and, consequently, costs must be realized in a way that meets customer targets.” PLANNED MAINTENANCE IS IMPORTANT FOR MACHINERY
Hakan Aydogdu, President of the Machine Tool Industrialists and Businessmen`s Association (TIAD), emphasized the indispensability of the machine tool and mold-making sector in production. Aydogdu noted that 12.5 percent of machine tools sold in Turkey in 2014 were used in mold production. He said, "This share was 18 percent in 2015, but considering the orders received, this has increased to 26 percent."
In his speech, Aydogdu emphasized that the rate of planned machine maintenance in Turkey is quite low, resulting in significant losses. Aydogdu emphasized that this rate is below 5 percent, saying, “The rate of machinery malfunctioning due to untimely maintenance is 70 percent. Poorly maintained machinery results in labor loss, the production of faulty parts, increased setup times, increased workplace accidents, and increased energy consumption. The benefits of planned and periodic maintenance can lead to a 25-35 percent reduction in maintenance times, a 35-45 percent reduction in breakdowns, and a 100-125 percent increase in production capacity.”
MOLD SUMMIT GROWTH THE SECTOR
Can Okatan, Mold/Equipment Manager for the Subsidiary Industry Development and Quality Department of TOFAS Purchasing Directorate, stated in his speech that the National Mold Summit, initiated five years ago by UKUB, has brought significant benefits to the industry. He noted the significant momentum it has gained. Emphasizing that this is the first time a plastic injection molding product has been designed and manufactured for a passenger car in Turkey, Okatan said, “While bi-material molds used to be sourced only from abroad, today we have numerous alternatives within our domestic molding portfolio. For the first time in the Fiat world outside of Italy, the dashboard product design was carried out at TOFAS, with molds designed and manufactured in Turkey.”
Can Okatan stated that they are not currently importing any large molds requiring high visual and functional performance, such as door panel assemblies, console assemblies, sill trims, and trunk liners. He added, “The molding companies we work with are making investments to increase their capacity and capabilities. They are increasing their exports by responding to the projects we have undertaken together, not limiting themselves to the domestic market.”