This article outlines the value of historical data as it relates to physical conditions outside of the normal process control measurements normally monitored. It will provide three primary examples of what physical data should be recorded, and how to use that information to identify changes occurring within the original molding conditions.
Rare is the occasion that you will find me writing an article in first person. However this article is best presented with analogies and 30 years past experience. Initially I covered 10 scenarios that occur which cause “scientific molding” based companies to fail in their utilization of the principles they attempt to practice. There were many more I could outline, but to prevent readers from sleeping through my soap box episode, I only gave 10 reasons. The article received huge response, and excellent feedback. In revisiting this article, I will revise the first ten and include another five.. bringing the total to 15….
Process adjustments result in a multitude of possible results, both good or bad. Process adjustment in regards to machine response can be compared to older style radios with knobs designed for both broad and fine tuning. The larger knob can be adjusted for aggressively adjusting frequencies to get to the station you want. The smaller knob allows for fine tuning of a particular station.
This article addresses various process changes a processor has available when making process adjustments to new or poorly performing processes . It will outline specific parameter changes, their potential outcomes.. as well as specific problems to look for after adjustments have been made. It also provides insight on how long it takes for specific changes to take effect ….
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……
By Garrett MacKenzie
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…
By Garrett MacKenzie
Plastic injection processing has experienced massive change in the last 20 years. The days of molding by time and pressure have given way to molding by position, peak pressure and robust process. RJG and John Bozzelli were major pioneers in the development of decoupled and scientific molding as the procedures were developed and given structure. Plastic injection as an “art” gave way to plastics processing as a science of repeatable, standardized processes.
By Garrett MacKenzie
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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The Leadership Network: Jeffery Liker
You can only imagine how exciting it was for industrial engineers and researchers when they were conducting research to understand the strategy and tools behind Toyota’s meteoric growth.
All the studies showed that Toyota was faster, with less costs and inventory, and delivering a higher quality compared to the American and European automakers. And it wasn’t by a small amount; Toyota used a small fraction of the inventory yet built cars on time every day with high quality…..
by John Beaumont
The Beaumont Effect is recognized as the source of mold filling imbalances and product variations in molds
with four or more cavities. The worst failures caused by the phenomena can be most easily (visually) recognized
in molds with 8 or more cavities. However, shear induced melt variations impact every injection molded
part, with a greater influence than most realize….