PLASTIC INJECTION MOULDING DEFECTS PREVENTION & ROOT CAUSE ANALYSIS
INTRODUCTION FOR PLASTIC INJECTION MOULDING DEFECTS PREVENTION & ROOT CAUSE ANALYSIS
Specifically designed for the practicing designer and molder.
This workshop focuses on prevention methods for defects and developing systematic root cause analysis skills. For solving molded-part defects and improving part quality problems.
- How to prevent defects from occurring in the first place?
- Eighty % of plastic parts problems originate from poor design.
- Gap analysis between DFM (Design for Manufacturing best practices) and your actual problems
- Root cause analysis
- Troubleshooting injection moulding defects in a systematic manner
- Implementing sustainable measures in place to prevent defects recurrence
- Scientific explanations on why these problems occur
This course is recommended for those who wish to improve their preventive & problem solving skills in plastic injection moulding design and process. It is also highly beneficial to companies aiming to improve productivity and optimise their injection moulding design and process methodology. A variety of people will benefit from this course. They include:
- Any technical personnel involved with plastic injection moulded parts
- Participants must already have the basics of injection moulding technology.
- Customer to provide ahead 5 top common issues that they have and the specific parts so that the trainer can use these as case studies during the training for optimum training effectiveness.
- Interactive and action based with personal examples.
- Combination of short lectures, visual presentations, workshops, demonstrations, simulations, and games.
- More emphasis is placed on workshops to allow the participants to learn the material presented in a fun and easy manner.
- 14 hours online
- Plastic drying
- Drying time
- Drying temperature
- Types of dryers
- Moisture measurement
- Overdrying effect
- Process optimization & scientific molding
- Optimization of injection phase
- Cavity balance
- Pressure drop
- Process windowGate seal time
- Cooling time
- Screw speed & back pressure
- Surface Defects
- Flow lines and jetting
- Splay (moisture or trapped air)
- Haze, blush, and poor gloss
- Mold mark
- Gate blush and gate splay
- Ink smearing
- Incomplete molding
- Race tracking
- Moldflow simulation errors
- Burning and Contamination Problems
- Burn marks and black specks
- Burn streaks
- Discoloration or poor color match
- Physical Problems
- Short shots
- Sink marks
- Vacuum voids and bubbles
- Ejector marks
- Geometry Maintenance Problems
- Under- or over-sized dimensions
- Poor dimensional repeatability (poor Cpk)
- Warpage and bowing
- Structural Defects
- Cracking, crazing, and brittleness
- Weld lines
- Stuck parts and pin push marks
- Long gates and plugged gates
- Drag marks and mold damage
- Break during assembly
- Break after usage
- Troubleshooting Procedures and Logic
- How to effectively approach, analyze, and implement troubleshooting procedures.
- Exploring Root Causes
- Explore the root causes of the various defects from the perspective of the plastic material as it fills, compresses, and cools within the cavity.
- Part Defectives and Potential Solutions
- How to avoid potential design-related problems?
- How to optimize the part quality with process-related solutions?
- Troubleshooting Guides (The Good, The Bad, The Efficient)
- A comparison of the different troubleshooting guide formats, including which tend to be most effective for solving molded part problems.
- Evaluating Attendees’ Molded Part Samples
- Defective part samples brought in by the participants will be discussed in a group format.
- An understanding by the participants of the processing conditions or a current process set-up sheet will greatly facilitate this discussion.