Reduction of production time and costs with optimized processes Analysis of a real case: construction of inserts for die-casting molds MMC HITACHI TOOL ENGINEERING EUROPE GMBH MEMBER OF MITSUBISHI HITACHI TOOL ENGINEERING, Ltd. FORM S.r.l. - Via Vittorio Veneto, 12/G - 35020 LEGNARO - PADOVA - ITALY www.formstampi.it

Insert in fix side of the mold: Steel 1,2343 ESU 46/47 HRC Oggetto: As first project we focused on the construction of inserts for molds for a particular casting with high production volumes. Currently, 4 molds are in production and 40 replacement inserts are built annually for these molds by Form, hence the interest in reducing the time and costs of construction. Insert in fix side of the mold: Steel 1,2343 ESU 46/47 HRC Dimensions d.200 x h.80 mm General tolerance 0.01mm FORM S.r.l. - Via Vittorio Veneto, 12/G - 35020 LEGNARO (Z.A.) - PADOVA - ITALY - www.formstampi.it - tel. 049.790.571-049.883.01.20

Objectives: Reduce process times of the insert by bringing on the cavity zone a general allowance of + 0.07mm, eliminating the need of a roughing electrode (and its relative milling hours) reducing the hours of EDM (Electro Discharge Machining). Creation of a new optimized, stable and repeatable production process to save time and production costs. FORM S.r.l. - Via Vittorio Veneto, 12/G - 35020 LEGNARO (Z.A.) - PADOVA - ITALY - www.formstampi.it - tel. 049.790.571-049.883.01.20

Current situation - starting point: Construction phases: Roughing milling 29 % Constr. of electrode for roughing EDM 24 % Constr. of electrode for finishing EDM 24 % Roughing and finishing EDM 23 % Total (reference starting point): 100 % FORM S.r.l. - Via Vittorio Veneto, 12/G - 35020 LEGNARO (Z.A.) - PADOVA - ITALY - www.formstampi.it - tel. 049.790.571-049.883.01.20

Projection with MMC HITACHI TOOL: Construction phases: Roughing and pre-finishing milling 30 % Constr. of electrode for finishing EDM 24 % Finishing EDM 5 % Total (compared to the reference): 59 % FORM S.r.l. - Via Vittorio Veneto, 12/G - 35020 LEGNARO (Z.A.) - PADOVA - ITALY - www.formstampi.it - tel. 049.790.571-049.883.01.20

Development: Days for the development of the whole project together with the staff of Form Srl: • internal development MMC Hitachi tool: 2 days • development of the Cam Hypermill strategies 1 days • development of the Cam Powermill strategies 1 days • side by side with the milling operator 3 days Total: 7 days Number of new Hitachi MMC tools required: 26 FORM S.r.l. - Via Vittorio Veneto, 12/G - 35020 LEGNARO (Z.A.) - PADOVA - ITALY - www.formstampi.it - tel. 049.790.571-049.883.01.20

Results: The agreed objectives have been achieved and confirmed with a saving on production time of -40% and a saving on production costs of -24% The test was carried out on 3 different milling machines and related operators, obtaining the same results, demonstrating the fact that a stable and replicable process was created The new process can be further optimized by bringing an additional quantifiable advantage between 15% and 20% as a reduction in production time. It is possible to extend the optimizations made to standardize processes to other projects CURRENT SITUATION SITUATION WITH MMC HITACHI TOOL FORM S.r.l. - Via Vittorio Veneto, 12/G - 35020 LEGNARO (Z.A.) - PADOVA - ITALY - www.formstampi.it - tel. 049.790.571-049.883.01.20