Báo cáo nghiên cứu khoa học: Development of a logistics system for the mold industry in the North of Vietnam

1.1.3 General assessment of the logistics situation 91.1.4 The research model proposes factors affecting the sustainabledevelopment of the logistics industry in industry in Vietnam 91.2

VIETNAM NATIONAL UNIVERSITY, HANOI

INTERNATIONAL SCHOOL

SCIENCE RESEARCH TOPIC

DEVELOPMENT OF A LOGISTICS SYSTEM FOR THE MOLD

INDUSTRY IN THE NORTH OF VIETNAM

Supervisor: Assoc Prof Nguyen Nhu Tung Candidate: Hoang Thi Phuong Huyen

Nguyen Thi Mai HuongLai Thuy Dieu

Vu Thanh PhuongNguyen Ngoc Oanh

Hanoi, 17 April 2024

TEAM LEADER INFORMATION

Program: Industrial Systems

Engineering and Logistics

Address: Thach That - Ha Noi

Phone no /Email:

0988455582/22070217@vnu.edu.vn

II Academic Results (from the first year to now)

III Other achievements:

Certificate of participation in Round 1 of Istartup 2023

There are many volunteer activities and participating in the Youth Union

Students with 5 good grades at the grassroots level in the 2022 - 2023 school year.School entrance scholarship

IV Student/ Group of students :

No Full Name ID Class Phone Email

1 Hoang Thi Phuong

Huyen

22070217 ISEL2022A 0988455582 22070217@vnu.edu.vn

2 Lai Thuy Dieu 22070081 ISEL2022A 0398137936 22070081@vnu.edu.vn

3 Nguyen Thi Mai

Huong

22071176 ISEL2022A 0357659226 22071176@vnu.edu.vn

4 Vu Thanh Phuong 22070126 ISEL2022A 0387453445 phuongvt@vnuis.edu.vn

5 Nguyen Ngoc Oanh 23070202 ISEL2023A 0388130753 23070202@vnu.edu.vn

Advisor

(Sign and write fullname)

Nguyen Nhu Tung

Hanoi,17 April 2024

Team Leader

(Sign and write fullname)

Hoang Thi Phuong Huyen

1.1.3 General assessment of the logistics situation 91.1.4 The research model proposes factors affecting the sustainable

development of the logistics industry in industry in Vietnam 91.2 Overview of the logistics system for the companies in the mold industry 10

1.3 Overview of the logistics system for the companies in the mold industry in

1.4 Analysis of previous studies to provide the directions to overcome the

1.4.1 Difficulties in the logistics system in the mold industry 13

CHAPTER 2 INVESTIGATION OF MOLD INDUSTRY AND LOGISTICS

2.4 Result of investigation of the mold industry and logistics systems for mold

2.4.1 Investigation of the mold industry in Vietnam and especially in the

2.4.1.3 Current status of mold manufacturing technology in Vietnam 182.4.2 Investigation of the logistics systems for the mold industry in Vietnam

2.4.3 Analysis and evaluation of the advantages and disadvantages of thelogistics systems for the mold industry in Vietnam and especially in the

2.4.4 Synthesize models of logistics systems and propose a logistics systemmodel for the mold industry in Northern Vietnam 22

CHAPTER 3 DEVELOPMENT OF THE LOGISTICS SYSTEM FOR MOLD

3.1.1.1 Injection Mold Manufacturing Process 263.1.1.2 The process of manufacturing stamping dies 30

3.1.2 Production Process and Utilization of Mold 363.1.2.1 Injection Mold Utilization Process 363.1.2.2 Stamping Mold Utilization Process[10] 393.1.2.3 Aluminum Die Casting Mold Utilization Process 39

3.3.1 Logistics System Design Results for Mold Manufacturing Plants 453.3.2 Logistics System Serving Hot Forging Mold Manufacturing Plants 473.3.3 Design of After-Sales Service Center Serving the Mold Industry 49

3.3.4 Results of the Information Management System Design in the

3.3.4.2 Input Inspection Information System 57

3.3.4.5 Transportation to Production Facilities 61

LIST OF FIGURES

Figure 1.2 Vietnam model market growth in the period 2011-2014 (trillion

Figure 2.1 Allocating model businesses in localities 18Figure 2.2 Level of technological responsiveness of Vietnamese enterprises 20Figure 2.3 Outbound Logistics Operational Process 24Figure 2.4 Difference Between Inbound Logistics and Outbound Logistics 25

Figure 3.3 Mold Design – Plastic mold manufacturing process 28Figure 3.4 Testing and assembly of molds in the plastic mold manufacturing

Figure 3.8: Components of Plastic Extrusion Die 34Figure 3.9 Solidworks Mold Design Software Design 36Figure 3.10: Overview Diagram of Plastic Injection Molding Production Process37

Figure 3.11: Preparation of Billet Meeting Quality Standards in terms of SurfaceSmoothness, Non-Warping, and Aluminum Composition as per Regulations 40Figure 3.12: Stretching and Cutting Process of Aluminum Die Casting Products41

Figure 3.13: Packaging for Warehousing or Transfer to the Next Surface

Treatment Stage such as Electrostatic Painting or Anodizing 42

Figure 3.14: Operation Process of Mold Manufacturing Plant 46Figure 3.15: Layout of Mold Manufacturing Plant 47Figure 3.16: 3D simulation model of Mold Manufacturing Plant 47Figure 3.17: Operation Process of Mold Manufacturing Plant 48Figure 3.18: Layout of Hot Forging Mold Utilization Plant 49Figure 3.19: 3D simulation model of Hot Forging Mold Utilization Plant 49Figure 3.20: Flowchart of the process at the after-sales service center (Model 1)50

Figure 3.21: Flowchart of the process at the after-sales service center (Model 2)52

Figure 3.22: Flowchart of the process at the after-sales service center (Model 3)53

Figure 3.23: Layout of logistics center for mold industry 54Figure 3.24: Information of receiving party sending party 55

Figure 3.38: Information fields of products in the warehouse 64

The mold industry stands as a formidable force in global manufacturing, serving as

a cornerstone for numerous sectors including mechanical manufacturing, plasticproduction, wood processing, food processing, and product packaging Its pivotalrole lies in furnishing the essential tools requisite for the production of a diversearray of goods across various industries Yet, while advanced economies such as theUnited States, Japan, and China have ascended to the pinnacle of mold industrydevelopment, operating at level 4 where proactive research, material selection, andinnovative mold design and manufacturing reign supreme, Vietnam finds itself at aless mature stage, lingering at level 2

At this juncture, Vietnam's mold industry predominantly revolves aroundmachining and assembly, lacking the advanced capabilities synonymous with itsmore developed counterparts Compounding this issue is the heavy reliance onimported machinery and equipment, with nearly 100% sourced from advancedeconomies like the US, Japan, and China Consequently, the establishment of anefficient logistics system tailored to cater to the mold industry's needs withinVietnam is imperative yet remains significantly overlooked in developmentdiscourse

The criticality of this oversight cannot be overstated For Vietnamesecompanies operating within the mold industry, the absence of a concerted focus onlogistics infrastructure poses formidable challenges Without a robust logisticalframework in place, obstacles such as supply chain inefficiencies, delayedprocurement processes, and regulatory bottlenecks persist, hindering the industry'spotential for growth and innovation

In light of these realities, it becomes abundantly clear that the time is ripe forVietnam to prioritize the development of logistics systems tailored specifically tothe mold industry By doing so, the nation can unlock untapped potential, fosteringtechnological advancement, enhancing economic competitiveness, and fortifying itsposition within the global manufacturing landscape Thus, the imperative to addressthe logistical needs of Vietnam's mold industry emerges not merely as an option but

as an indispensable catalyst for industrial progress and prosperity

CHAPTER 1 OVERVIEW OF THE LOGISTICS SYSTEMS FOR

MOLD INDUSTRY 1.1 Overview of the general logistics system in the industry

1.1.1 General overview of industrial logistics systems

- Industrial logistics system is the process of managing and operating activities related

to transportation, storage, and distribution of goods from the source to the finalcustomer It includes activities such as warehouse management, packaging, shipping,order processing, and information management

- Objective: Optimize the process of transporting and storing goods to ensure efficiencyand cost savings New technologies such as IoT, artificial intelligence, and blockchainare being applied to improve industrial logistics systems

1.1.2 The role of logistics in industry

a) Increase production efficiency

- Increase productivity efficiency: Logistics helps optimize the production process bydelivering the necessary raw materials and materials at the right time and place,helping to reduce waiting times and costs

- According to DHL research, process optimization helps increase production efficiency

- According to a PwC report, optimizing the logistics process can help increase sales

[12]

c) Cut the cost

- Logistics helps reduce the costs of transporting, storing, and managing goods byoptimizing processes and using advanced technologies

- The use of advanced technologies in logistics can help reduce transportation costs

minimizing costs by 57.7% [14]

e) Increase flexibility

- Logistics helps increase flexibility in the production and transportation process,helping businesses adapt quickly to changes in the market and customer needs

- Efficient logistics organizations will have higher productivity and competitivenessbecause they can reduce operational costs and provide quality services to their

customers.[15]

1.1.3 General assessment of the logistics situation

- Currently, the logistics situation in the industry in Vietnam is improving.Investment in transportation infrastructure, especially seaports and airports, hashelped improve cargo transportation capacity In addition, logistics companiesare also developing and providing more professional logistics services

- According to the General Department of Vietnam Customs, in June 2023, thetotal value of Vietnam's imports and exports of goods (based on actual importand export data until June 25 and estimated for the remaining days) is estimated

to reach 56.01 billion USD, up by 3.6% compared to the previous month(equivalent to an increase of 1.93 billion USD) This is one of the factors

pushing Strengthen the development of the logistics industry in Vietnam [16]

- By 2020, despite the significant impact of the Covid-19 pandemic, the volume

of goods passing through the seaport system reached 692.3 million tons,accounting for 78.7% of the total volume of goods through ports During theperiod of 2016-2020, the volume of goods through seaports increased by

61.8%, averaging about 10% per year.[17] This shows the improvement of

maritime transport infrastructure in Vietnam Male

- However, there are still some challenges facing the logistics industry inVietnam, including a shortage of highly qualified human resources, anunoptimized management system, and limited legal regulations This can affectthe service quality and efficiency of the logistics industry

- According to a report from the General Statistics Office of Vietnam, Vietnam'sLogistics Performance Index (LPI) in 2018 reached 3.05/5, ranked 39/160countries This shows that many challenges still need to be resolved to improve

the quality of logistics services in Vietnam [18]

1.1.4 The research model proposes factors affecting the sustainable development of the logistics industry in industry in Vietnam

Based on the practice of developing Vietnam's Logistics industry and systematicallysynthesizing research on factors affecting Vietnam's Logistics industry, the authorproposes a model to research factors affecting development—sustainable development

of Vietnam's Logistics industry

Figure 1.1 Proposed research model

1.2 Overview of the logistics system for the companies in the mold industry.

1.2.1 Logistics aspects in the mold industry

- Material and mold management: Logistics begins with the management of raw

materials required for mold production This includes ensuring materials are purchasedand delivered to the mold factory on time and with quality In addition, molds alsoneed to be effectively managed to ensure production readiness

- Production Management: Logistics in the mold industry involves managing the

mold manufacturing process This includes production planning, managing themanufacturing process, and ensuring that molds are produced properly and ontime

- Transportation Management: Transportation is an important aspect of logistics

for the mold and die industry This involves transporting raw materials to thefactory and transporting molds from the factory to other locations or tocustomers Route management, shipping options, and shipping costoptimization are important factors

- Warehouse management: Companies in the mold industry often need to

maintain warehouses to store raw materials, molds, and finished products.Warehouse management requires optimizing storage space, controllinginventory, and ensuring products are ready for delivery to customers whenneeded

- Supply Chain Management: Supply logistics involves managing the entire

process from sourcing raw materials to the final product This includesoptimizing the supply chain to ensure material and product continuity

- Information technology: Information technology and information systems play

an important role in logistics management for the mold industry Warehousemanagement systems, order management systems, and related technologies helptrack and manage processes effectively

- Risk management: Industrial logistics also involves handling risks during the

transportation and storage of goods, including the risk of loss, fire, and otherexternal factors that can affect the supply chain

1.2.2 Domestic mold market

- Current status of the mold industry: The supporting industry in particular still

faces many difficulties and challenges, partly due to not being proactive aboutmold-making technology Currently, domestic enterprises can only meet therequirements of mold production to manufacture consumer mechanical products partlyaccording to orders from foreign joint venture companies For products with hightechnical requirements (washing machines, refrigerators, air conditioners, cars,motorbikes, etc.), semi-finished products/molds must still be imported from abroad for

production.[19]

- Logistics in the mold industry: Domestic mold manufacturing enterprises

currently operate in a closed state, with no coordination or connection to design andintensively produce one or several aspects products of the same type, so althoughthere are units that have invested in several relatively modern technological lines, there

is still duplication causing resources to be scattered

Due to small production, even alloy steel imported to make molds has a very highprice This explains why the mold production costs of Vietnamese enterprises arealways high, leading to limited production efficiency and competitiveness

Vietnam's mold market in 2014 reached over 21 trillion VND (equivalent to 1.0billion USD) This is a significant increase compared to 2012 (at 13 trillion VND) In

2013, the capacity of Vietnam's mold market reached approximately VND 19 trillion.The reason for the sudden growth in 2014 is due to increased demand frominternational corporations that are investing heavily in Vietnam such as Samsung,Cannon, Microsoft mobile, etc In general, in the period from 2011 - 2014, Vietnam's

mold market grew rapidly at a rate of about 18%/year [19]

Figure 1.2 Vietnam model market growth in the period 2011-2014 (trillion

VND)

- The size of the Vietnamese mold market compared to other countries

In the ASEAN region, Vietnam's mold market is an attractive market

The domestic mold manufacturing industry has not been highly appreciated bydomestic businesses for complex molds Businesses using molds often think thatdomestic molds do not meet the requirements of accuracy, difficulty, durability, andcomplexity as well as a large number of molds in a short time Therefore, the number

of businesses producing products with high technical requirements choosing to order

or buy molds from abroad is quite large

Country/region Number of businesses Market (million USD)

Table 1.1 Mold market size in Vietnam compared to countries

1.3 Overview of the logistics system for the companies in the mold industry in the North of Vietnam.

The logistics system for mold industry companies in Northern Vietnam includesactivities related to transportation, storage, and goods management Mold industrycompanies need to transport products from factories to agents or customers To ensurethe transportation process goes smoothly, businesses need an effective Logistics

system

The logistics system for Northern mold industry companies includes the followingactivities:

- Transportation: The company needs transportation vehicles such as trucks,

containers, and boats to transport goods from the factory to agents or customers

- Storage: Companies need warehouses to store goods before shipping or after

receiving goods from the factory

- Goods management: Companies need a goods management system to ensure

smooth transportation and storage This system includes information about the

quantity of goods, date of manufacture, expiration date, storage location, etc

- Shipping partners: Companies need reliable shipping partners to ensure smooth

and safe shipping

- Cost Management: Companies need a cost management system to ensure

efficient and cost-effective transportation and storage

In summary, the logistics system for mold industry companies in Northern Vietnam

is very important to ensure the smooth and efficient transportation and storage ofgoods

1.4 Analysis of previous studies to provide the directions to overcome the

limitations of the existing system.

1.4.1 Difficulties in the logistics system in the mold industry

In the mold industry, the logistics system may face some special difficulties due tothe special nature of this product Below are some specific difficulties that logisticssystems in the mold industry may face:

a) Large Size and Weight:

Molds often have large sizes and weights, these molds are often used for theproduction of large products, such as automotive parts or metal processing industries,sizes can range from meters to several meters and the mass can range from severalhundred kilograms to several tons This can increase the cost and complexity ofshipping and storage

b) Special Storage Requirements: Molds often require special storage

conditions to ensure that they are not damaged or altered during transport andstorage

- Die Casting Molds: Maintains anti-corrosion coating

c) Diverse Supply Chain:

Molds are often produced from many different sources, requiring management of

a diverse supply chain and ensuring consistency in the production process

d) Time Required for Repair and Maintenance:

When a mold needs repair or maintenance, waiting time can be an issue,especially if the mold is a critical part of the manufacturing process

e) Customs and Legal Requirements:

If there is international shipping, customs and legal requirements can be achallenge It is necessary to ensure compliance with all international regulations andrules

f) Lack of information and transparency: Many businesses in the mold industry

in Vietnam may have difficulty tracking and managing information about thelogistics process This lack of transparency can lead to uncertainty and difficulty insupply chain management

g) Limited infrastructure: Logistics infrastructure systems in some areas may

not be developed enough to meet the transportation and storage needs of the moldindustry

h) The working process system is still limited, resulting in unoptimizedoperating costs

i) Lack of specialized warehouses, lack of transportation, and lack ofspecialized scale for the mold industry

j) Quality human resources for mold production are still limited

[10]

1.4.2 Recovery methods

To overcome these difficulties, businesses in the mold industry often need toinvest in smart logistics systems, use modern technology, and build solidpartnerships in the supply chain

To overcome difficulties in the logistics system in the mold industry, thefollowing solutions can be implemented:

- Smart inventory management: Use a smart inventory management system to

track mold availability and forecast demand Optimize the ordering process

to minimize shortages or overstocks

- Supply chain optimization: Build strong relationships with quality and

reliable supply partners Use information systems to monitor and evaluatesupplier partner performance

- Mold information management: Use an information management system to

store and track information about each mold, including specifications, usagehistory, and current status Incorporate barcodes or RFID to easily track thelocation and storage of each mold

- Invest in technology: Use IoT (Internet of Things) technology to monitor the

environmental and shipping conditions of molds Integrating supply chainmanagement (SCM) software and shipping tracking software can helpimprove transparency and information management

- Transportation safety management: Identify and implement special safety

measures to ensure molds are not damaged during transportation Trainshipping staff and managers on safety procedures and handling rules

- Integrate the logistics system with the production process: Integrate the

logistics system with the production process to ensure that molds are alwaysready when needed Optimize production and shipping schedules to reducewait times and optimize performance

- Ensure customs and legal compliance: Master customs and legal regulations

related to international shipping Work closely with experienced logisticspartners in handling customs procedures

- Implement a periodic maintenance strategy: Plan and implement periodic

maintenance for molds to minimize the risk of incidents and increaselongevity

- Pay attention to the impact of climate change: Review and adjust

transportation and storage schedules based on climate change to reduce risks

1.5 Conclusions of chapter 1

In this chapter, we have presented an overview of important aspects related to thelogistics system of the mold industry in Vietnam, especially in the Northern region.First, we provide a comprehensive overview of the logistics system in the industry,focusing on the important role of logistics and proposing a model to researchfactors affecting the sustainable development of logistics in the Vietnameseindustry

Through an overview of industrial logistics systems, we have better understood theimportance of logistics in optimizing production and distribution activities Inaddition, assessing the current logistics situation has helped us identify challengesand opportunities in the process of industrial development in Vietnam, providingdeeper insights into the logistics system of transport management Transportationand warehousing directly serve this industry The proposed research model offers acomprehensive approach, considering important factors that may influence thefuture development of the logistics industry

CHAPTER 2 INVESTIGATION OF MOLD INDUSTRY AND LOGISTICS SYSTEMS FOR MOLD INDUSTRY IN NORTH OF

2.2 Content of survey research.

- Aspects of the mold industry: scale, structure, and development trends

- Current status and production and operation capacity of the maintechnologies that Vietnam has compared to the world

- Industry-specific technologies and tools and how to apply them in moldmanufacturing

- Current status and prospects of the logistics system in the mold industry

- How to organize and manage the logistics system, including: processes,operating principles and influencing factors

- Explore the role of technology in improving and optimizing logisticssystems

- Learn about the development of the dry port system and logistics centers

2.3 Survey method

Survey type: Online survey

We use websites on the Google platform to survey, collect and analyze data andinformation about mold businesses in the Vietnamese market

Although online data collection has many advantages, such as saving time andcosts, there are also disadvantages such as difficulty in controlling and selectinginformation Surveying directly from businesses is an important thing in the studentresearch process, however, we encounter some difficulties in that process such asarranging time to visit businesses and conduct face-to-face surveys, internalregulations and the company's privacy policy

But we still try and try with the hope that the final result will bring value andmake a positive contribution to our research field

2.4 Result of investigation of the mold industry and logistics systems for mold industry in the North of Vietnam.

2.4.1 Investigation of the mold industry in Vietnam and especially in the North of Vietnam.

2.4.1.1 Mold enterprise in Vietnam

The die-casting industry in Vietnam has developed since the 1990s and isbecoming an industry with great potential Currently, Vietnam's die-casting industry

is developing strongly, especially in the North

According to statistics as of 2014, in Vietnam, 383 companies are operating inthe field of mold manufacturing, mainly small and medium companies Companiesare concentrated mainly in Hanoi, Ho Chi Minh City, Dong Nai, and the Pacific HoChi Minh City alone concentrates more than 40% of the country's mold enterprises(83% of plastic enterprises are concentrated in the Ho Chi Minh City area) If youfeel like Dong Na, the southern region accounts for more than 70% of the number

of molding enterprises in the country.[1]

In addition, Nam currently has 355 FDI enterprises investing in mold production

to serve international corporations in Vietnam such as Samsung, Hyundai, Toyota,and Canon Among Vietnamese enterprises, more than 50% focus on meetingdomestic market needs at low cost technology and output requirements While theremaining companies are constantly upgrading and investing in advancedtechnology and new generation machinery, simulation design software is designed

to shorten time and improve product quality to participate in the value chain ofvarious industries such as electronics, automobiles, etc., and become partners of

international corporations.[1]

According to the Ministry of Trade and Industry, by 2020 there will be about1,500 enterprises operating in the field of mold manufacturing, of which more than80% are concentrated in the North The value of the die casting and precisionengineering industry in Vietnam currently exceeds 1 billion USD per year Inparticular, with a growth rate of 18%/year, this field is attracting the attention ofmany domestic and foreign investors It is worth noting that Vietnamese companiesonly produce 8.5% of injection molds and the remaining types of molds

Figure 2.1 Allocating model businesses in localities

2.4.1.2 Production and consumption.

Significant growth According to the Ministry of Trade, domestic moldproduction increased by an average of 15-20%/year in the period 2015-2020

Demand for molds is also increasing, especially from export manufacturers [21]

Mold products in the plastic, aluminum, and rubber industries will still accountfor a large market share in the total mold market in Vietnam According to theVietnam Plastics Association (VXA), plastic stone has grown steadily since 2011.Reaching 1.7 billion USD in 2011, 2.5 billion USD in 2013 and 3 billion USD in

2014 Average plastic consumption per capita in Vietnam has also increased rapidly

in recent years years: In 1989 it was only 1.1 kg/year, in 2008 it was 27 kg/yearand in 2020 it was 45kg

However, Vietnam's mold industry still faces many challenges such ascompetition from countries in the region, lack of high-quality human resources, andnot meeting international quality standards

The domestic mold manufacturing industry is not highly appreciated by domesticconsumers for its complex molds Businesses that use molds often think thatdomestic molds cannot meet the requirements for accuracy, difficulty, durability,complexity as well as a large number of molds in a short time Therefore, thenumber of enterprises producing high-tech products choosing to order and buymolds from abroad is quite large

2.4.1.3 Current status of mold manufacturing technology in Vietnam

a) Design technology

Along with the general trend of the world, Vietnam's design technology todaymainly relies on appropriate computer tools and software Vietnam's designtechnology level is assessed to be equivalent to about 68% of the world level Thisgap mainly focuses on three finished product technologies: conceptual design,

simulation, and optimal design Vietnam's overall design is still weak compared tothe world, mainly due to the lack of copyrighted software and ineffectiveexploitation of software features Among businesses involved in designing andmanufacturing molds, only 20% are willing to invest in design technology and 80%

of businesses only use free or cracked software due to the high investment costs

software copyright Highly adaptable design and modules.[1]

In addition, our country still lacks high-quality human resources with experience

in designing complex mold structures as well as understanding technologicalprocesses and advanced machining methods

b) Machining technology

The level of machining technology is estimated to be equivalent to 69.92%compared to the world In machining technology, the technologies that play themost important roles are creating computer-aided machining programs (CAM -Computer Aided Manufacturing), milling and turning These technologies still have

a relative gap compared to the world, reaching 65 - 75%.[21] Some technologies

have equivalent levels in the world such as wire cutting, electric spark, and cooling.However, these technologies play a small role in mold processing

Vietnam is still using many old generation processing machines, 2 to 3generations away from developed countries Compared to China, Vietnam is about

a generation behind, when China started using many machining centers in moldproduction

c) Heat treatment and surface treatment technology

Heat treatment technology is a relatively specific technology and is widelyapplied in many mechanical industries and fields In the field of molds, Vietnam'sheat treatment technology level is estimated to be equivalent to 68.2% compared to

the world average [2]

Heat treatment facilities are relatively common at mechanical factories inVietnam; however, the technology and equipment of these facilities do not meet therequirements for high quality molds Therefore, these products often have to beshipped to FDI enterprises or taken abroad for heat treatment

One of the reasons why the level of heat treatment and surface treatmenttechnology in the country is still quite far from the world is due to high investmentcosts while the market is not large enough and specialization in the community Thebusiness community is not yet high Therefore, businesses do not have enoughinvestment capital or face high risks in recovering capital due to an insufficientnumber of regular orders

d) Alkaline measuring and assembly technology

Testing technology in Vietnam is mainly controlled before and after processing.Dynamic measurement technology during machining is rarely applied due tolimited equipment and high quality of workers Mold enterprises also do not care

about measurement technology and often underestimate the level of quality theimportance of this technology Vietnam's measurement and testing technology level

reaches 78.75% in the world [21]

Assembly is the final stage of the manufacturing process The role of assemblydepends on the structural characteristics and technical requirements of each type ofmold For molds with simple structures, not large volumes, and few details,assembly is not too important and can be done by hand with common tools Formolds with complex structures, large volumes, high requirements for accuracy,joints and assembly play an important role, the assembly process requires highlyqualified workers, using specialized tools specialized tools Currently, Vietnam's

technology level is equal to 76.25% of the world level [21]

Through analytical data on the importance and level of component technologies,

it can be seen that Vietnam is still weak in a number of technologies that play animportant role among component technologies, including milling technology,Simulation, analysis and machining (CAM) plays the most important role formolds products, followed by component technologies in thermometers and design

Figure 2.2 Level of technological responsiveness of Vietnamese enterprises

2.4.2 Investigation of the logistics systems for the mold industry in Vietnam and especially in the North of Vietnam.

Currently, the mold transportation process in Vietnam is mainly done by road,using cars In addition, other methods such as railways and waterways are alsoused To ensure shipping quality, people often use unmanufactured molds to helpreduce weight and shipping costs, and apply protective measures such as oiling toavoid corrosive oxygen during transportation, ensuring that the mold samplereaches its destination with quality intact Businesses also kept records of eachmold shipment, including production date, shipping schedule, and destination,helping to create a detailed and easy-to-follow information system Confirming

mold condition after shipping and documenting any damage helps provide effectiveremediation.

The Logistics Information System (LIS) is understood as an interactive structurebetween people, equipment, methods, and processes aimed at providing relevantinformation to logistics managers with the goal of planning, executing, and

controlling logistics effectively.[24]This is not only about arrangement, marking,

maintenance, and inspection, but also includes more complex and diverse activities

to ensure that the transportation process, warehouse management, and overalladministration are carried out promptly and effectively

Mold location management: Organizing warehouses by area creates conveniencewhen selecting, maintaining, and replacing molds A few businesses have beenusing barcode/RFID systems to track the exact location of each mold, ensuringtransparency and speed in the warehouse management process

- Quality control processes including inspection, maintenance, andreplacement are also strictly monitored Maintenance and replacementprocedures are crucial to mold performance and longevity Businesses havealso evaluated and recorded detailed maintenance history, usage times, andother information related to each mold, creating an important database tohelp track performance and maintenance cycles nourishment

2.4.3 Analysis and evaluation of the advantages and disadvantages of the logistics systems for the mold industry in Vietnam and especially in the North of Vietnam.

The logistics system of the mold manufacturing industry in Vietnam, especiallythe Northern region, is developing strongly but some limitations still exist.According to the report, the logistics industry in Vietnam is growing faster than thecountry's GDP growth rate However, the logistics system of the mold industry inVietnam is still facing many challenges, including difficulties in transporting goods,lack of infrastructure, and insufficient professional human resources

Advantage:

- The value of the mold industry today is a great advantage for moldmanufacturing businesses developing on the global supply chain Statesupport for trade activities, exhibitions, specialized promotions for domesticmold products as well as foreign currency loans and import taxes on theinternational market

- Information management systems are increasingly developing to helpbusinesses manage easily mold storage information, track location, andcondition as well as design change and repair information

- Professional logistics businesses are increasingly expanding and providingdiverse services, from transportation to storage and warehouse management

- Northern Vietnam is the economic and industrial center of the country, with afavorable geographical location with more than 3,200 km of coastline andmajor international ports in the North such as Hai Phong, and importantindustrial areas In addition, the railway, road, and air systems in the North

are being upgraded and developed, helping to improve the ability to transportmolds.

Defect:

- Due to limitations in design and manufacturing capacity, most moldmanufacturing enterprises in Vietnam have not had systematic andsynchronous investments in technology, which leads to very high wastagerates in production large, the production process has not been optimized

- Enterprises need coordination across the value chain, most of them operate

in a self-contained state, and have not linked together to design andintensively manufacture one or several products of the same type to achievetheir goals The general goal is high-quality products, and low prices,causing resource dispersion

- Cost and time have not been optimized as the mold transportation processmay require in-depth knowledge and special skills

- Some businesses may not effectively integrate information systems tomanage and monitor the logistics process closely, leading to information lossand poor performance

2.4.4 Synthesize models of logistics systems and propose a logistics system model for the mold industry in Northern Vietnam.

● Inbound Logistics:

Inbound Logistics is the initial stage in the Logistics value chain system and isalso the process of controlling the source of raw materials or semi-finished productsfrom manufacturers or suppliers before being put into production export,structuring, this process is in charge of many activities such as raw materialprocessing, control, distribution to inventory control, and storage of goods

This is the most important stage, deciding and directly affecting the followingstages to create the final finished product before consumption More specifically,guaranteed input sources will help businesses increase revenue, reduce costs, andmake the final product of the best quality, improve customer satisfaction whenusing the product If input Logistics operates inefficiently and is not guaranteed, itcan cause businesses to increase production costs, reduce revenue sources, andwaste input materials Therefore, Inbound Logistics is a very complex stage andrequires the parties involved to be meticulous and accurate from the beginning.Inbound Logistics process:

- Step 1: Purchasing and Sourcing: identify businesses and evaluate suppliers,negotiate prices, and purchase raw materials

- Step 2: Recording and Receipts: businesses record orders and receivereceipts after payment

- Step 3: Notification: when transporting raw materials, the supplier willelectronically declare the shipment's tracking information to the business

- Step 4: Load Arrival: moves received goods to the yard/warehouse orconsignee as designated by the business

- Step 5: Receiving: staff loads and unloads goods, scans barcodes, and takesinventory to ensure compliance with orders After that, the goods will betransferred to the production warehouse at the factory, or production facility

to continue production activities

- Step 6: Reverse Logistics: the team receives and transports orders fromcustomers returned due to defective goods, problems in delivery, repair, etc

● Outbound Logistics:

If Inbound Logistics undertakes the first stage of the supply chain, OutboundLogistics will undertake the post-production stage to bring the product to the finalconsumer In other words, Outbound Logistics is the process of transporting,storing, and distributing goods to stores and final consumers

Outbound Logistics requires businesses to be meticulous when implementing.Because this process includes many different steps Therefore, to ensure thatOutbound Logistics always run smoothly, businesses need to ensure the following 3factors:

First: Choose the appropriate distribution channel Distribution channels have therole of storing, promoting products, and arranging for sale to customers on behalf ofthe business Therefore, to optimize revenue and costs, businesses need to chooseappropriate distribution channels, have a good Logistics system, and serve the righttarget customers

Second: Have a storage and inventory management system To ensure theOutbound Logistics process runs smoothly, businesses need to have a suitablestorage and inventory management system to avoid the following risks:

- If there is too much inventory without selling it all, the products may bedamaged and outdated

- If the inventory is too small, it will not be able to meet customer needs.Therefore, to ensure inventory, businesses can use historical data to predictdemand and inform distribution channels In addition, businesses can also use the

"just in time" (JIT) system, always ready for orders, start production, order rawmaterials and provide products correctly, sufficiently, and on time

Third: Optimize delivery activities Transportation and delivery are an importantpart of Outbound Logistics Therefore, optimizing transportation activities will helpbusinesses save more cost dynamic businesses need to choose a delivery methodthat suits the product and order requirements Transportation activities ensure costsavings, safe delivery, and goods are delivered to the right location within thespecified time

Inbound and Outbound are seamless cycles consisting of small activities linkedtogether to ensure the flow of goods from input to output of the business

Outbound Logistics process:

- Step 1: Customer Order: customers place orders through the business's saleschannels

- Step 2: Order Processing: the business confirms the order, receives therequested quantity and checks whether the inventory is enough to meet theorder.

- Step 3: The business confirms the order and receives the requested quantity

of products Order replenishment (Replenishment): at this stage, the reserveinventory will be transferred to the main storage warehouse, replacing theproduct the customer has purchased This process may trigger the production

of more goods or the need to order raw materials from suppliers to maintainstable inventory levels

- Step 4: Picking: warehouse staff selects goods from the reserve warehouse tocomplete the order

- Step 5: Packing, Staging & Loading: staff pack, label, and documentaccording to internal and customer requirements Then, the staff funds toload the goods onto the truck

- Step 6: Shipping & Documenting: Orders leaving the warehouse are shipped

to distributors or partners At this time, the Company's system will record theshipment and send detailed information to customers for tracking

- Step 7: Last Mile Delivery: shipping order from the distributor to the final

consumer.[25]

Figure 2.3 Outbound Logistics Operational Process

Figure 2.4 Difference Between Inbound Logistics and Outbound Logistics

2.5 Conclusions of chapter 2

Through in-depth analysis of the production and consumption markets and thecurrent status of the mold industry in Vietnam, especially the North, we haveapplied many different research methods to collect data and analyze result Theresults show the strong development of this industry in recent years, with asignificant increase in the number of businesses operating in the field of moldmanufacturing and the industry value achieved However, when focusing onanalyzing and evaluating the strengths and weaknesses of existing systems, werealize the fragmentation and lack of systems in the logistics services of businesses.From there, we built a proposal for a theoretical model of a logistics system servingthe mold industry suitable for the Northern region of Vietnam We find it necessary

to establish a specialized logistics center to serve the mold industry This center willplay an important role in providing high-quality logistics services, includingpackaging, warehousing, mold transportation, preservation, and regularmaintenance In particular, the center will focus on optimizing processes tominimize risks and ensure flexibility in the supply chain

With support from this logistics center, the mold industry in Vietnam will havethe opportunity to develop stronger, improve competitiveness in the internationalmarket, and contribute to the prosperity of the country's economy

CHAPTER 3 DEVELOPMENT OF THE LOGISTICS SYSTEM FOR MOLD

INDUSTRY IN THE NORTH OF VIETNAM 3.1 Design Foundation

3.1.1 Research on Mold Manufacturing Process

3.1.1.1 Injection Mold Manufacturing Process

● Structure and General Function of Injection Molding Mold [8]

Figure 3.1: Components of an injection mold

- Some Basic Components in the Structure of Plastic Injection Molds (17 maincomponents):

6 Water lines 7 Cellular plate 8 Wear plate

9 Rail 10 Pin clamp

plate

11.Ejector PinRetainer Plate

12.Bottom clampplate

13 Ejector pins 14 Spring 15 Return pin 16 Guide

bushing17.Guide pin

Table 3.1 Some main parts in plastic injection molds

- Structure:

Figure 3.2: Detailed components

The plastic injection molding machine is divided into two main parts: the clampunit and the injection unit

The clamp unit comprises the stationary clamp and the movable clamp Thestationary clamp is used to clamp and secure the stationary mold, and precisepositioning is ensured through locating rings on the mold and locating holes on themachine

The injection unit is responsible for transforming the plastic material from solid toliquid by temperature and injecting the molten plastic into the mold under pressuregenerated by the screw and nozzle system

In addition to these two main parts, the injection molding machine can also besupplemented with additional components such as cooling systems, robots, or othersupport systems

● Plastic Injection Mold Production Process

Step 1: Product/Blueprint Research

The required input information includes: [33]

Product material

+ Product weight

+ Selection of mold type: 2-plate mold or 3-plate mold

+ Number of cavities in the mold

+ Cold runner or hot runner system

+ Type of gate: point gate, submarine gate, edge gate, etc

+ Material for mold cavity

+ Material for mold core

+ Production output

+ Other relevant information

Step 2: Mold Design - Plastic Mold Manufacturing Process

After researching the product/blueprint and obtaining necessary information aboutthe product, the design engineers will propose and design the mold This is a crucialprocess in the plastic mold manufacturing process This stage will determine theoptimal outcome of the product, providing direction for the mold manufacturing

process to ensure accuracy and ease of production [34]

Figure 3.3 Mold Design – Plastic mold manufacturing process

Step 3: Mold Machining and Manufacturing

In the plastic mold manufacturing process, this stage requires the use of precisionmachinery and equipment to accomplish:

- Machining of Mold Inserts: The selected steel blocks are cut into standard-sizedmetal components In this process, milling machines are used to mill edges,surfaces, and flat grind the outer surfaces of the plastic mold inserts

- CNC Machining: CNC machining is performed to shape the mold cavity andother mold components CNC machines accurately mill the steel blocksaccording to the design drawings

- Wire EDM Machining: Wire EDM machines produce highly precisecomponents with a tolerance of only 0.005mm

- Electrical Discharge Machining (EDM): This step is responsible for shapingareas where CNC machining or wire EDM cannot reach

- Finishing Machining: This stage involves creating water lines, creating boltholes, etc

- Polishing after Machining: Polishing and smoothing out machining marks.Inspection and treatment of vents, dulling or chamfering of permissible areas,and thorough cleaning The surface quality of the plastic product dependsentirely on the smoothness of the mold cavity, so this process is carried outmeticulously and accurately The polishing process is always performed in twostages: preliminary polishing before assembly and meticulous polishing afterassembly.

Step 4: Assembly and Inspection

This is the final step to complete the plastic mold manufacturing process After allthe mold components are finished, assembly is carried out Before assembly, it'snecessary to inspect all components according to quantity and specifications to ensurethat they all meet the required standards

Figure 3.4 Testing and assembly of molds in the plastic mold manufacturing process

The assembly process requires very high precision to ensure that the mold produceseffective products when put into operation The mold plates, cores, bases, and moldcavities are assembled into a complete mold unit

Step 5: Mold Trial Compression

To ensure that the mold operates properly and meets the initial requirements of thecustomer, the mold will undergo a trial operation after assembly is complete Theplastic mold manufacturing process will be considered complete if the trial moldedproducts meet the requirements Any errors will be rectified before delivering themold to the customer

Step 6: Delivering the Plastic Mold to the Customer

3.1.1.2 The process of manufacturing stamping dies

● Materials for making stamping dies

The materials used for manufacturing stamping dies are typically selected based onspecific requirements of the manufacturing process, the type of die to be fabricated,and technical factors such as hardness, durability, and resistance to wear Here aresome common types of materials used for stamping die production:

- Tool Steel: Tool steel is the most common choice for manufacturing stampingdies Tool steels typically exhibit high hardness, good heat resistance, and ease

of machinability Popular types of tool steel include P20, H13, S7, and D2

- Alloy Steel: Alloy steel can provide better hardness and strength compared toordinary carbon steel Alloying elements such as chromium, vanadium,molybdenum, and nickel are added to improve the mechanical properties of thematerial

- Stainless Steel: In some special cases where high corrosion resistance isrequired, stainless steel can be used for manufacturing stamping dies

- Aluminum: Aluminum is an alternative choice for lightweight applications orwhen good lightweight and hardness are needed However, aluminum typicallycannot withstand high pressures and is less durable compared to steel

- Copper and Brass: Copper and brass can also be used for specific applications,but they are less common due to limitations in pressure resistance anddurability

● The process of designing and manufacturing stamping dies involves severalstages:

- Stage 1: Force Calculation and Blanking

The first step in the stamping die manufacturing process is to calculate the stampingforce for the metal blanks It is essential to calculate the stamping force accurately onthe die components, minimizing the force deviation to ensure minimal deformation ofthe blanks The magnitude of the force depends on the material and thickness of themetal sheet [1]

- Stage 2: Selection of Stamping Machine

In this step, a suitable stamping machine is chosen to accommodate the mold It'sadvisable to select a machine capable of providing greater stamping force thanrequired by the die and adjustable power.[1]

- Stage 3: Dimension Calculation of the Mold

Based on the sample product or product drawings, suitable dimensions for the moldare calculated All these dimensions are represented in the design software, facilitatingthe machining and assembly of the mold [1]

- Stage 4: Mold Design

After obtaining detailed information about the dimensions of each mold component,engineers proceed with designing the complete die using specialized software togenerate 2D or 3D drawings of the finished die

Figure 3.5 Images of stamped mold design

- Stage 5: Mold Machining

Based on the design, the mold is machined using CNC machines to create acomplete physical mold This machining process is similar to plastic mold machining.However, due to the high pressure involved in stamping, the stamping die must beheat-treated to achieve the required hardness, toughness, elasticity, and high wearresistance to achieve optimal performance

During the above stages, a 3D laser scanning machine can be used to assist inmeasuring the dimensions of the sample product or the machined mold to calculatedimensions and check the finish of the mold [1]

Sequenc

e

number

Machining step Documen t number Iron tooling Machining equipment Operator

6 Finish mill

cavity O0005 T5-Ball millR3xL100 CNC VF4 Mr DucHieu

Table 3.2 : Machining cycle

+ Polishing the Mold with Laser:

Polishing removes material from the surface Conversely, laser tool machines heat athin layer of material from about 20 to 100 micrometers The machine includes a5-axis port and a 3-axis laser scanning head, allowing the machine to approach theblank from all sides Many mirrors are used to reflect the laser beam when peelingspeeds exceed 1m/s, even on small surfaces

The product before and after being polished by laser The laser beam is directlyadjusted by CAM data from the 3D CAD model of the polished part

Depending on the material being polished, the machine can produce surfaces with a

Ra of 0.1 to 0.4 micrometers However, in cases where precise accuracy is needed,such as those commonly used for glass molds and forming tools, speeding up thepeeling rate can be up to 10 times or using cheaper integrated devices

+ Polishing the Mold by Grinding Stone:

The mold grinding machine is a small, easy-to-use machine with many featuresused to grind dowel holes, smooth weld seams, sharp edges at small, narrow, andconfined positions (grinding scissors) Used to create mold can also cut, drill, polishvarious materials, small details

After cutting, grinding the chisel, it is necessary to check the size of the chisel tosee if it meets the accuracy requirements as specified in the manufacturing drawing[5]

- Stage 6: Assembly

Figure 3.6 Assembly Process for Stamping Die

- Stage 7: Inspection, Evaluation of Results

Total product inspection is the final step, if the product meets the requirements, it isdelivered, if it does not meet the requirements, the product is redesigned