INTRODUCTION TO PLASTIC INJECTION MOULDING – MOLD SETTER AND SETUP TECHNICIAN TRAINING

This program that involves plastic injection moulding – mold setter and setup technician training covers the die-setting process from start to finish with an emphasis on safety. Proper procedures for mold inspection, preparation and installation are outlined. Injection Mold Setup also covers setup procedures for hydraulic, toggle and hydro-mechanical clamp systems.

COURSE OBJECTIVES

• Material preparation, drying and mixing
• Screw and barrel cleaning
• Guidelines for setting each processing parameter
• Procedures for proper injection velocity profile set-up
• Proper clamp and part removal settings
• Understanding the 3 types of consistencies required in Injection Molding
• Discusses how changing processing conditions affects molded part properties
• Reduce rejects and scrap
• Improve part quality
• Increase productivity

COURSE CONTENT

• Safety
  • Dangers
  • Proper dress
  • Personal Protective Equipment (PPE)
  • Eye protection
  • Ear Protection
  • Safeguards
  • Good housekeeping
  • Lockout/Tagout
  • Press inspection
  • Handling tools
  • MSDS

• Moulding Operations
  • Molding process
  • Terms
  • Molding machine operation
  • Components
  • Controller
  • Accessing and loading stored information
  • Mold mounting system
  • Mounting – step by step
  • Unloading – step by step
  • Alignment
  • Temperature control system
  • Raw material
  • Part inspection
  • Screw/barrel cleaning procedure
  • Molding machine parameter optimization

• Surface Defects
  • Flow lines and jetting
  • Splay (moisture or trapped air)
  • Haze, blush, and poor gloss
  • Orange peel and surface ripples
  • Gate blush and gate splay

• Burning and Contamination Problems
  • Burn marks and black specks
  • Burn streaks
  • Contamination
  • Discoloration or poor color match

• Physical Problems
  • Flash and short shots
  • Sink marks
  • Vacuum voids and bubbles
  • Blisters and delamination

• 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

• Troubleshooting Procedures and Logic
  • How to effectively approach, analyze, and implement troubleshooting procedures.

• Steps in setup optimization
  • Process sheet
  • Waterline diagrams
  • Mould temperature maps
  • Setup Instructions
  • Operator Instructions

• Molding process
  • Process cycle
  • Molding parameters
  • Multi-steps injection
  • Molding machine maintenance
  • The 6 steps process optimization

INTENDED AUDIENCE
These 2 days workshop has been designed for Technicians and Senior Technicians who are involved in the process of Mold Setup and Plastic Injection Molding and want to make their workplace more productive & optimized.

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

METHODOLOGY

• Class room training: 70%
• Genba training on the production floor: 30%
• Interactive and action based with personal examples.
• Customer to select their top 5 critical issues to be used for troubleshooting training together with samples

DURATION

• 2 days

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