INTRODUCTION FOR RJG SYSTEMATIC MOLDING

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”

These are some of the common complaints heard on 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?

Scientific and Systematic Molding are terms used for methods of setting up and maintaining robust and repeatable processes. This methodology includes having a thorough understanding of the molding system, clear reasons for all process settings, comprehensive process documentation and a systematic troubleshooting approach when things go wrong. A key to implementing this type of strategy is a thorough understanding of the FOUR key plastic variables in molding.

COURSE OBJECTIVES

If given appropriate support on-the-job, these new knowledge and skills should translate into:

• Reduced part variability and scrap
• Optimized the cycle times
• Reduced time spent on troubleshooting
• Exercise greater control over the molding process
• Improve part quality
• Increase productivity

INTENDED AUDIENCE

This 2 days workshop has been designed for all Owners, Section Heads, Engineers, Senior Technicians and Tool makers who are involved in the process of Plastic Injection Molding and want to make their workplace more Productive.  Participants are encouraged to bring along the common problems, defects that they face in day to day operations.

METHODOLOGY

Presentation, video, activities-based exercise, discussion based on actual case study or problems faced.

DURATION

2 days

COURSE CONTENT

• Introduction to Systematic Molding
  • The Molding Process
  • The 3 types of consistencies required in Injection Molding

• The 5 main Factors in Plastic Injection Molding
  • Part design
  • Material selection
  • Mold design & construction
  • Machine selection
  • Molding process

• The 4 Plastic Injection Molding Main variables
  • Plastic Temperature
  • Plastic Flow
  • Plastic Pressure
  • Plastic Cooling

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

• The 6 steps process optimization
  • Injection phase
  • Cavity balance study
  • Pressure drop study
  • Determining the Process Window
  • Gate seal time study
  • Cooling time study

• Action plan

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