OVERVIEW OF PLASTIC INJECTION MOULDING-SETUP TECHNICIAN TRAINING:

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 be 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 at the Injection Molding workshop when we have an instable process. How to 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
• Reduce rejects and scrap
• Improve part quality
• Increase productivity

DURATION :

• 2 days

INTENDED AUDIENCE :

• Setup technicians
• Supervisors

METHODOLOGY:

• 70% classroom & 30% on the machine
• 1 machine will be used as sample

Sample mould and testing material to be ready

COURSE CONTENT :

Safety

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

Moulding Operations

• Molding process
• Terms
• Molding machine operation
• Mold mounting system
• Temperature control system
• Raw material
• Part inspection
• Screw/barrel cleaning procedure
• Moulding machine parameter optimization

Steps in setup optimization

• Process sheet
• Waterline diagrams
• Mould temperature maps
• Setup Instructions
• Operator Instructions

The 3 types of consistencies required in Injection Molding

Mould qualification

• Mould qualification procedure
• Checklist

The 6 steps process 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.

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