INTRODUCTION TO PLASTIC INJECTION MOULDING – PROCESS OPTIMIZATION AND TROUBLESHOOTING

Are you familiar with the following sounds of instability:

• The process cannot be repeated.
• Every startup turns into trouble shooting
• 10 minutes of troubleshooting turns into a full day of knob turning & adjustment
• “Injection molding process must always be tweaked”
• “Something has changed. We will compensate by adjusting. Find out the root cause later”
• “This part can only be molded by Technician A. Call him in now.”
• “It’s a design problem” – but you have molded good parts before.
• “The tool must been modified” – but you have been running good parts on this tool for years
• Why we can produce good parts in Europe but not when the tool is transferred to Malaysia?

These are some of the common complaints heard on the Injection Molding workshop when we have an instable process. This Plastic Injection Moulding – Process Optimization And Troubleshooting program can overcome these problems that increases your material scrap cost, takes up machine valuable time and saps your energy.

COURSE OBJECTIVES

• Understanding the 3 types of consistencies required in Injection Molding
• Understanding the 5 critical Factors of Injection Molding
• Explores the injection molding process with focus on making process improvements
• Discusses how changing processing conditions affects molded part properties
• Explains specific rules for controlling the plastic during processing
• Provides thorough overview of injection molding and troubleshooting techniques.
• Exercise greater control over the molding process
• Troubleshooting techniques
• Improve part quality
• Increase productivity

COURSE CONTENT

• Process Optimization
  • optimization of injection phase
  • cavity balance
  • pressure drop
  • process window
  • gate seal time
  • cooling time
  • screw speed & back pressure

• Trouble Shooting common issues at customer location
  • Detailed discussions on customer’s 5 specific issues

•  Troubleshooting Procedures and Logic
  • Root cause definitiHow to effectively approach, analyze and implement troubleshooting procedures.

• Exploring Root Causes
  • Explore the root causes of the various defect from the perspective of the plastic material as it fills, compresses and cools within the cavity.
  • How to prevent these root causes from arising?

INTENDED AUDIENCE
This two days workshop has been designed for all Section Heads, Engineers and Senior Technicians who are involved in the process of Plastic Injection Molding and want to make their workplace more productive & optimized. A variety of people will benefit from this course. They include:

• moulding engineers
• process engineers
• project engineers
• manufacturing engineers
• any technical personnel involved with plastic injection moulded parts

PREREQUISITE

Participants are expected to have a basic understanding in Plastic Injection Molding with a minimum of 2 years experience.

METHODOLOGY

• Day 1 & 2 will be conducted at Gemba.
• Customer is expected to get 1 machine prepared together with mold, material and 1 PIC
  (Interactive and action based with personal examples.)
• Customer to provide their top 5 issues 2 weeks before the training starts

DURATION

• 2 Days

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