Plastics processors are responsible for making process corrections when defects affect their scrap rate. One of the most common defects in plastic injection is splay. Splay adjustments can be a simple fix, or several hours of babysitting a press and head scratching. This article will help to identify various forms of splay, as well as common (and less common) causes. It will also provide various solutions for removing splay from your process….
Plastic Injection Troubleshooting:
Using Scientific Molding Approach When Validated Processes Fail
Many companies apply scientific principles to their set up and validation of processes. After all, this methodology has proven its worth as a successful approach in process development. However, it is important to note that SM goes beyond set up. The true test of processors is how they evaluate change in validated processes that have already been proven. This article will define criteria that identify root causes for change and provide information and approaches to evaluate and correct changes that occur…
By Garrett MacKenzie- Plastic411 Editor
One of the trickiest materials to mold with is Nylon. The material itself has great molded in properties, such as strength and when used properly visual aesthetics. Using the material itself, however can sometimes require a strong molding approach to prevent molding variances and defects
This article will address some common problems that occur in nylon molding. It will identify many of the normal molding conditions that are common with this material, as well as provide some insight into processing approach that can help to reduce, and even eliminate scrap events….
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…