1. CADWELD PLUS Redesign Outline

2. Goal
Part 1:
Redesign CADWELD PLUS that will have all the benefits of the PLUS at the quality of traditional or better.
Repeatable quality welds
Mild and controlled reaction
Part 2:
Optimize product and process that will yield savings.
Mold Standardization for manufacturability
Redesign molds to use less graphite

3. CADWELD PLUS Pie Mold Weld Metal Cup
Weld Metal Flow
Slag Separation
Gas Interaction
Heat Flow
Fit-up with Cable/Rail
Graphite
Reaction Containment
Weld Metal
Contamination
Cupric/Cuprous Ratio
Controlling Raw Materials
Mixing/Separation
Formulation
Particle Size
Purity
Cup
Heat Transfer
Weld Height-to-Width ratio
Mold Interaction
Graphite Interaction
Mylar&Shrink Band
Need 2/3 Pies to be optimized to get a good consistent weld every time

4. CADWELD PLUS Pie Weld Metal Cup Optimized Molds (Phase 1)
Need 2/3 Pies to be optimized to get a good consistent weld every time
Cup

5. CADWELD PLUS Pie OPTIMIZED CADWELD® PLUS Optimized Molds (Phase 1)
Optimized Cup
(Phase 2)

6. CADWELD PLUS Improvements Plan Brief Phase 1: Molds
Mold Optimization and Standardization: Implementation ongoing through 2011
Improve weld quality, reduce graphite, reduce manufacturing time
Optimize mold design for best weld performance
Use minimum graphite, while achieving best weld performance
Redesign for CNC batch manufacturability and update manufacturing process
Standardize by size and family & update design standards
Molds
Improve slag separation
Reduce blank size
Commonize design within size and family
Reduce number of features difficult to machine

7. CADWELD PLUS Improvements Plan Brief Phase 1: Covers
Mold Optimization and Standardization: Implementation ongoing through 2010
Improve weld quality, reduce graphite, reduce manufacturing time
Cover Redesign:
Reaction intensity becomes milder by about 10-20%
More economical to manufacture
Easier to clean
Improving Weld Quality
Improved durability for the mold-hinge-cover system is under the fatigue endurance limit (3”x3” covers were tested 8,000+ cycles)

8. CADWELD PLUS Improvements Plan Brief Phase 2: Cups
Cup Consolidation (detail on later slide)
Improve weld quality, reduce graphite, increase manufacturing capacity
Optimize cup shape for optimum heat transfer&flow
Improve slag separation and weld quality
Calm the reaction
Reduce CUP machine and RTS setup time
Grouping I:
15, 25, and 32
Grouping II:
45 and 65
90 and 115
Grouping III
150 and 200
Grouping IV
250 and 300
400 and 500

9. CADWELD PLUS Improvements Plan Brief: Other
New Mold Cleaning Tools
Easy to use and fabricate
Easier to use
Less expensive to manufacture
Expected to result in less “mold lock ups” and improve mold wear slightly
Small: Sizes 15, 25, 32, 45, and 65
Medium: Sizes 90, 115, 150, 200
Large: Sizes 250, 300, 400, and 500
Igniter Improvements
Improve ignition reliability, reduce scrap, and decrease cost
Igniter stickout improvement on 250 and 300 – Completed
Phase 1: Pre-punched igniters with large ignition surface: September 2009
Phase 2: Updated igniter station: September 2010

10. The program starts with
Size 15

11. CADWELD PLUS Improvements Sizes 15
Use 32 size cup with 15 weld metal
Redesign molds to have a weld as good or better to traditional in current configuration
Production is able to make consolidated 15 CW+ easier than current CW+15 15 25 32
Current Mold
New Mold
optimized tap hole
deeper crucible for new consolidated cup

12. CADWELD PLUS Improvements Sizes 15
Phase 1 and Phase 2: Mold Redesign and Cup Redesign
Size 15: Implementation:
New Molds Cleaning Tool: July 2009
Mold production: Starting August 2009
All Weld Metal (F20 and F33)
Mold Redesign covers 99.2% of all molds sold (Testing Covers All)
New Cup production: October 2009
Traditional
Old Cup
New Cup
Old Mold
Not Compatible
(Replace Mold)
New Mold

13. Plan for CADWELD 15, 25, and 32 Size 15: 10/01/2009

14. FAQ Will we offer something for trade in of old molds?
Yes – we can offer the partner a discount towards new molds. We can also offer the customer/partner discounts on all competitor molds they want to send in also.
Will the old handles work on the new molds?
Molds are identical for handles and clamps
Will the new molds cost the same?
Costs should go down because of less graphite. Market will expect to see some type of reduction, so we will come up with some list price reduction.
What about MTO molds?
All molds that have sales between 2006 and 2009 will be changed. Molds outside of that timeframe or MTO will go through the BPM event process to be re-designed.
Does the part numbers change?
No – this is a running change
Does the flyaway program stay the same?
Yes
What do I do if my customer calls me and says “ the cup is sticking out” ?
Verify the condition
Offer to replace the mold via flyaway program and discount mold
How do I tell if the customer has old or new CWP?
The cup size is physically changed and the date code on the box would be post 10/2009.

15. Questions