spe injection molding training presentation
TRANSCRIPT
Society of Plastics Engineers (SPE) - Hennepin Technical College - March 29, 2016
“Training Today’s Personnel in the Science of Plastics Processing”
Paulson Training Programs
▪Lead Provider of Scientific Plastic Processing Training
▪Established in 1977
▪Over 50,000 Trained by PTP During the Past 38 Years
▪3,000+ Companies Use Paulson Training
▪Products & Services Developed in Cooperation with Industry Experts and Product Advisory Boards
Q: Why Start Training?
A: Secret: You’ve already started
▪Lost production efficiencies (cycle time, reject rate, downtime)
▪Broken, damaged equipment▪Wasted resin▪Excessive time to 1st in-spec part▪Efficiency differences between shifts▪Cost of finding/replacing workers▪Unmotivated employees
Why Train?
Efficiency of a Molding PlantIs measured by:
Quality of Data-driven decisions:
▪ Cycle time▪ Scrap▪ Uptime/Downtime▪ Labor costs
Overall throughputConversion of raw materials into sell-able finished goods.
A sample of the practical tools
▪ Short shot analysis ▪ Balance of fill analysis▪ Gate freeze study – used for
cold gate molds mostly though some application to hot gates as well
▪ Vent viability test – This test is standard to determine if the vents are adequate.
▪ Hot spot analysis – Steel temps taken on various parts of the mold to determine balance of BTU extraction.
▪ Optimal fill rate analysis- Rheology curves etc.
The Economics of Injection Molding What is Effective Throughput?
▪Is it Cycle time?▪Low scrap rate?▪First time quality?▪Full Cavitation?▪Low labor content?▪Utilization?▪Efficiency?
YES!It’s all of these!
What do you sell?
▪Plastic parts?...........NO- What was ordered
▪Finished goods?......NO- What you produced
▪Labor?.....................NO- Cost
▪Service?..................NO- Expected
▪Efficiency?...............NO- Cost driver
▪Quality?...................NO-Expected
▪Skill/Talent?.............YES - Without it you lose
▪Time?......................YES!
Teaching Plastics Processing from the “Plastic’s Point of View”Physics doesn’t change. Plastic reacts to just four basic variables*: Heat, Flow, Pressure, and Cooling. This is the foundation for all injection molding training.*As discovered by plastic engineer and educator Donald C. Paulson.
The Four Primary Plastic Conditions
Plastic Melt Temperature
▪Frequently is not the same as the barrel temperature settings (common misconception)
▪Must be measured to actually know what effect the screw speed and back pressure are having on true melt temperature. ▪30/30 method with Pyrometer and
melt probe
A Pyrometer is a MUST have.
Plastic Flow Rate
▪The next variable we MUST control▪Plastic is a Non-Newtonian visco-
elastic material▪Faster flow rates result in lower
viscosity
Plastic Flow Rate
▪Fill time is directly related to cycle time▪Less pressure equals less stress
• Non-Newtonian characteristics of plastics
▪Fill rate control allows the machine to adapt to inherent viscosity shifts in the resin while maintaining CONTROL of the process
Plastic Pressure▪Hold/Pack pressure is how we determine
structural integrity and final dimensions of the part. • Some folks think cooling time
establishes dimensions▪Hold pressure should not be confused
with Hold time▪Sometimes we need to profile pack and
hold pressure
Relationship of Fill Rate to Pack/Hold Pressure Fill rate control helps us adapt to intrinsic
viscosity shifts in the raw material. Pack/hold time establishes the final
dimensions of the part and it’s structural integrity.
Hold time is about gate freeze. If the gate doesn’t freeze we are not in control of our process. Many times hold time can be traded for cooling time.
Plastic Cooling Rate
▪Injection molding inputs heat energy (BTU’s) into the plastic, allowing plastic to flow and pack the cavity to achieve structural integrity. Cooling removes the heat energy thus converting the plastic to a net shape. ▪The mold is a very expensive
cooling fixture
Mold Temperature Control
< 5°∆T
What really matters...▪Product efficiency should be
monitored daily▪Low product efficiency is an
operational concern▪Is it cycle time?▪Cavitation?▪Machine stoppages?▪Conduct a Root cause analysis
followed by a Corrective action plan
Root Cause analysis (link)
What you need to know
▪Annual/Monthly requirements▪Material▪Material cost▪Part weight▪Cycle time▪Number of cavities▪Projected area
▪Packaging▪Machine rate▪Labor requirement▪Special Quality criteria▪Probable efficiency
(likely scrap rate)▪Set-ups per year
The Four M’s
Causes of variation in injection molded plastic product production▪Mold ▪Machine▪Material▪Man
Industry Observations
Problem statements:
There is a shortage of skilled process technicians in the industry today. ▪Evidence of this can be found on
almost every job posting site.▪Dozens of ads for Process techs
and/or Process engineers for Injection Molding.
Benefits of Training
▪Profitability• Reduced waste, improved cycle times, fewer
mistakes and other training benefits all add up in your bottom line.
▪Productivity• Trained employees solve problems quickly
and fewer problems occur.• Trained employees make better decisions on
the production floor.
▪Knowledge• Training develops a technically competent
workforce.• Training explains the “why”, not just the
“how”.
▪Consistency• Training develops consistency of techniques -
employee to employee, shift to shift, plant to plant.“The Paulson products
are EXCELLENT!” Jim Proffitt, Rubbermaid
Why Train with Paulson?
$26,000 Reduced Cycle Times Savings$15,000 Reduce Reject Savings$ 6,000 Reduced Credits Savings$47,000 Monthly Additional Profits$564,000 Annual Additional Profits
➢ Dramatically Improved Efficiency➢ Return On Investment➢ Increased Profits
▪Downtime Reduced by 32%▪Mold Change Time is 10%
Lower▪Revenue/Machine Hour
Improved 35%▪Scrap Parts Down 8% and
Production Up 15%
SkillBuilder™
World’s leading injection molding machine simulator
SkillBuilder Benefits▪Employees practice molding in
a safe environment and are not tying up valuable machine time, materials and resources.
▪Uses interactive training platform to improve processing knowledge - quickly. One hour of simulation practice is equal to 5 actual machine hours!
▪“Free Mold” for learning problems solving techniques and optimizing cycle times.
More SkillBuilder Benefits▪Provides structured tutorial to see
the effects of each machine control on melt temperature and part dimensions.▪Develops understanding of plastic
behavior under processing conditions.▪Reinforces the information
presented in training modules.▪Turns theory of processing into
reality.▪Turns knowledge into skill.▪Automatic record keeping of all
training activities
SkillBuilder Connects the Classroom with the Production Floor
What You Can Do With SkillBuilder
MORE Interactive Lab Lessons
Optimizing Machine Control Settings with SkillBuilder
Injection Molded Part Problems and Solutions
with SkillBuilder1. Optimizing the Melt
Temperature with an Amorphous Plastic
2. Optimizing the Melt Temperature with a Crystalline Plastic
3. Finding the Minimum Fill Time Required
4. Optimizing Part Dimensions5. Optimizing Part Weight6. Achieving the most efficient
Cycle Time
1. Getting Rid of Burnmarks
2. Molding to Precise Dimensional Tolerances
3. Controlling Flash on a Molded Part
4. Solving Sinkmark Problems
5. Identifying and Solving Voids in Molded Parts
6. Weldline Formation and Possible Solutions
Paulson Products and Services
“Great products, easy to use and dynamic 3-D graphics!” Ken Lewis, S&L Plastics
▪ Injection Molding Process Training
▪ Injection Molding Simulation
▪ Thin Sheet Thermoforming
▪ Twin Screw Compounding
▪ Sheet Extrusion Technology
▪ Extrusion Blow Molding
▪ Products in Multiple Languages
Injection Molding
▪Basic Molding Machine Operations
▪Practical Injection Molding
▪Optimizing Machine Control Settings
▪Injection Molded Part Problems & Solutions▪Hot Runner Molding Solutions
▪Implementing DECOUPLED MOLDING
▪Design of Experiments
▪SPC for Injection Molding
▪Efficient Mold Setting
▪Understanding Materials for Profitable Molding▪Plastics Drying Technology
“BESPAK has had a very positive experience using Paulson Interactive Training Programs. Not only all of our molding personnel, but many of our office & support staff have completed the training, which has given them greater insight into our primary manufacturing process of injection molding.” David Hepbrun, BESPAK
SM
Extruder Operationand Control Single Screw
1. The Single Screw Extruder: Parts and Operation2. The Structure of Plastic Raw Materials3. The Characteristics of Plastics for Extrusion4. Effects of Pressure, Temperature and Flow5. Optimizing Extruder Controls – Part 16. Optimizing Extruder Controls – Part 27. Safety, Pre-Start and Start-Up Procedures8. Steady-State Operation, Shutdown and
Maintenance Procedures9. Single Screw Extruder Troubleshooting
Thin Sheet Thermoforming
▪ Optimizing operating controls
▪ Safety around the thermoforming machinery
▪ Thermoforming for maximum efficiency and profit.
Operation of the machinery used in thermoforming
The function of each component of thermoforming line
Plastic behavior during the thermoforming process
Sheet extrusion fundamentals,
Extrusion Blow Molding Technology
Recognize processing conditions that affect quality
Analyze and solve practical blow molding problems
Develop a working knowledge of blow molding machinery
Evaluate and improve operating procedures
Compounding with the Twin Screw Extruder
Detailed video explanation of what is going on inside the extruder, and how control setting adjustments affect the plastic and output.
Describes optimal machine-running procedures with proven employee-learning models for more thorough, better-retained learning
Teaches in-depth operating skills for increased efficiency and productivity
Develops insight for quicker, more accurate troubleshooting and problem resolution
Strengthens process control skills for greater productivity and less waste
Sheet Extrusion Technology
▪ The Sheet Extrusion Line: Parts and Operation
▪ Sheet Extrusion Dies
▪ Controlling Plastic Flow in the Die
▪ Plastic Behavior in the Sheet Extrusion Line
▪ Pre-Start, Start-up, and Steady-State Operating Procedures
▪ Safety and Shutdown Procedures
▪ Troubleshooting the Sheet Extrusion Line
The Paulson Difference
“We’re pleased to add Paulson Training Programs to our group of affiliate partners. They have a well-established reputation due to top quality products and through years of providing advances in training such as their injection molding simulator, SimTech.” Bill Gruber, Concentric Custom Services
▪ 24/7 Cross platform deliverability. Phone, tablet, computer. Anytime, anywhere
▪ Innovative injection molding simulation teaching tools
▪Paulson Plastics Academy Tech Center
▪Seminars at your plant in Injection Molding, Thermoforming, Extrusion Blow Molding
Paulson Plastics AcademySeminars from the Paulson Plastics Academy teach the fundamentals of plastics engineering and scientific molding. All classes are led by expert instructors who bring to life the basics and advanced topics of injection molding.
Paulson Plastics Academy Seminar Titles ProMolder 1 ProMolder 2 Data-Driven Molding
Module 1 Set-Up Module 2 Process Module 3 Certification
Mold Design Fundamentals Managing a Molding Plant ProEx 1 ProEx Blow Molding
Paulson Plastics Academy Technical Center
Offering a whole new learning experienceLocated in sunny Florida, the Tech Center offers:
A dedicated, 9,000 sq. ft. injection molding training facility
Expert injection molding instructors Four injection molding machines for hands-
on machine time Multiple Classrooms Six-station computer lab, loaded with
Paulson courseware & simulator QC Lab
All-in-One Training Solution
Online
• ONLINE-TRAININGAnytime, anywhere
• REAL-TIME INTERACTIVEMolding simulation
OnSite• CUSTOM ONSITE
Customized training at your facility
HandsOn
• MULTI-CITY SEMINAR TRAININGHands-on and in person
• DEDICATED TRAINING CENTERClassrooms & Machines
Skilled People Come From Paulson
▪New Hires▪Machine Operators▪Process Engineers▪Supervisors▪Part Handlers▪Technicians▪Production Management▪CEOs
Partial List of our 3,000+ Clients
Winners Powered by Paulson
2005 - U.S. Farathane Corp.
2004 - Miniature Precision Components Inc.
2002 - (Tie) Tech Group Inc. & Precise Technology Inc.
2001 - Cascade Engineering Inc.
2000 - Tessy Plastics Corp.
1997 - Nypro Inc.
2015 – Evco Plastics
2014 - Stihl Inc.
2013 - Tech Molded Plastics Inc.
2012 - Hoffer Plastics Corp.
2011 - Steinwall Inc.
2010 - Plastikos Inc.
2009 - GW Plastics Inc.
2008 - Plastic Components Inc.
2007 - Innovative Injection Technologies Inc.
2006 - Mack Molding Co.
Plastics News – Processor of the Year
Industry Alliances and Partners
THANK YOU Society of Plastics Engineers, SPE
Hennepin Technical College and all attendees for your time today!
www.PaulsonTraining.comTed Chryzanowski
Powerful Training. Proven Results.