Category Archives: Articles

Eliminating the “Fire Fight” in Plastic Injection

Plastics production rides a fine line when the goal of low scrap, high yields and sustainable, repeatable systems are being developed. Without the proper approach, the system can  quickly fall into one of two categories: tribulation.. or turmoil. Quite often you will hear old school molders describing their battle for a robust processing system as “fire fighting” in the world of plastic injection molding. In real terms, “fighting fires” on the production floor is a sign of system failure. True molding standards don’t require constant coddling, adjusting, sorting, etc. It is real easy to fall into the trap of applying “Band-Aids” to molding situations when the proper approach should have been……

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Top 10 Reasons Molders Fail at Scientific Molding

TOP 10 REASONS COMPANIES FAIL AT SCIENTIFIC MOLDING

Rare is the occasion that you will find me writing an article in first person. I have always just felt that the best way to include my molding peers in the depth of the topics I cover is to put them in the driver’s seat. However this article is best presented with analogies and 30 years past experience. As such, I will be covering 10 scenarios that occur which cause “scientific molding” based companies to fail in their utilization of the principles they attempt to practice. Trust me.. there are many more I could outline, but to prevent readers from sleeping through my soap box episode, I will limit my scope to 10…..

 

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Effective Machine Shutdowns are Key to Successful Start Ups

By Garrett MacKenzie

press floor

The weekend comes to an end and the time comes to bring the molding floor back online for the beginning of a new work week. A molder can sometimes dread the tasks associated with a full plant restart. There are many potential failures that can occur as a plant is returned to a production state. Despite these risks, much of the headache can be avoided simply through proper shutdown and start up procedures. The following article addresses many key components that often lead to poor restarts. It also provides insight into some of the methods that can be implemented to not only reduce system breakdowns, but also can offer smoother start-ups with fewer problems…

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Plastics Technology Article: Optimizing Your Molding Cycle

By Garrett MacKenzie

optimize

It is possible for machines to run too fast—find the sweet spot where maximum output overlaps with good parts.

 

In today’s fast paced plastic injection industry, lean manufacturing is a primary driver of profitability. Without lean, organizations find their operations are sluggish and ineffective. This not only affects a company’s ability to successfully grow and prosper, but the capability of taking on new work also suffers because current systems have not been effectively streamlined. This article addresses cycle time optimization, outlining the different variables within the molding process that can be used to maximize profits.

 

One of the first points that needs to be made when addressing this topic is to acknowledge that it is possible for machines to run too fast. Every molding job is different, and the following conditions must be satisfied to properly assure that the optimization is successful……

 

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Laws of Viscosity in Molding

By Garrett MacKenzie

viscosity

Viscosity is a very large category that has huge effects on standardizing molding processes. It is also one of the most important  factors in a molder’s arsenal of making process changes. This article will first explain viscosity, and then delve into different situations where viscosity may help or be hurting  a processors goal of zero scrap and high output…..

 

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Use of Visual Management in Lean Manufacturing

By Garrett MacKenzie

5s2

I once had a plant manager who had the perfect analogy for the use of visual management, by implementing an engineered shop floor layout with clear and concise instructions at each employee’s workstation.

 The question he asked our team was this:
 “Why is it that when you look at a shampoo bottle, there are directions to ‘Rinse, Lather and Repeat’?” 
His answer was simple, yet thought-provoking. 

”Someone at some point stood there with the bottle, trying to figure out what to do with it.”

Simply put, the better you are able to remove complexity from the shop floor and provide concrete visual and descriptive aids, the more control you will have over your plant’s overall performance…..

 

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3 to 7 Minute Color Change

By Garrett MacKenzie: October 18, 2016

pellets1

In lean manufacturing, changeover times are a vital component of shop performance. Minimal down time assures that multiple changeovers have little effect on a plant’s available machine time available. After all, less down time in the production equation offers more opportunities to take on more work and increase company profits. This article outlines specific approaches towards color changes that will support the potential of completing color changeovers in 3 to 7 minutes. This may seem like an impossible task to some, but with the proper planning, methods and equipment,  it is an attainable and repeatable goal…..

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Optimizing Your Molding Cycle

By Garrett MacKenzie

In today’s fast paced plastic injection industry, lean manufacturing is a primary driver of profitability. Without lean, organizations find their operations are sluggish and ineffective. This not only affects a company’s ability to successfully grow and prosper, the capability of taking on new work suffers because current systems have not been effectively streamlined. This article addresses cycle time optimization, outlining the different variables within the molding process that can be used to maximize profits.

One of the first points that needs to be made when addressing this topic is that it is possible for machines to run too fast. Every molding job is different, and the following conditions must be satisfied to properly assure that the optimization is successful:………

Click HERE to read the article

Injection Molding 5 Lessons Learned– Steve Bremmer

Oftentimes in molding the same lesson has to be learned over and over the hard way, which is why I’m such a fan of utilizing high quality training for everyone who touches a molding machine. The following items are some basic lessons learned that I have seen repeated over the years…..

https://www.linkedin.com/pulse/injection-molding-5-lessons-learned-steve-brammer?trk=hp-feed-article-title-like