Defects Reduction of Plastic Injection Molding

Defects Reduction Of Plastic Injection Molding 1
STUDY OF PROCESS IMPROVEMENT ON MANUFACTURING SHOP FLOOR
(DEFECTS REDUCTION OF PLASTIC INJECTION MOLDING)
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Defects Reduction Of Plastic Injection Molding 2
Table of Contents
Abstract..................................................................................................................................................3
1.0 Introduction..................................................................................................................................4
2.0 Literature review...........................................................................................................................4
2.1 Continuous improvement.............................................................................................................5
2.2 Injection molding..........................................................................................................................5
2.3 Injection molding process.............................................................................................................6
3.0 Methodology.................................................................................................................................6
4.0 Results and discussions.................................................................................................................8
5.0 Conclusion...................................................................................................................................15
References.........................................................................................................................................16

Defects Reduction Of Plastic Injection Molding 3
Abstract
In order for a company to maintain its reputation and succeed in its operations, it is important to
take into consideration the possibility of occurrence of defects that would in turn have an effect
on the quality of the products that are produced by the company. The defects might occur due to
plastic processing through injection modeling. This study therefore examines how to minimize
the level of the defected parts per million (DPPM) that may be brought forward by a customer. In
order to minimize the level of this defects, it is necessary to accurately monitor the defects that
are noticed during the process of production, those observed by the in progress quality control
(IPQC) as well as the department of outgoing quality control (OQC). This study carries out a
critical analysis of the defects that are found in the said departments using the tools of seven
basic quality tools. It also takes a keen look into the most severe complaints that were raised by
the customers. Once all this is done, the origin of the defects are realized and real solutions
brought forward and the implemented in order to achieve items that are free from defects.
This research paper focuses on reported cases of poor quality in the injection moulding
department. The purpose is therefore to reduce the rate of rejection by the customer to 100
defected parts per million (DPPM) as well as managing the data in order to achieve a continuous
management plan.

Defects Reduction Of Plastic Injection Molding 4
1.0 Introduction
Quality control has consistently been used in ideally all kind of business enterprises. It is a
concept that not only focuses on the production areas but also on the service areas [1]
. Its use has proved to be the core for those companies that intend to increase their competitive
advantage. Improved quality of products and services will lead to greater success in the business,
lower costs, greater customer loyalty as well as improved competitiveness amongst other related
companies [2].
Worth noting is that in any given plant, continuous activities aimed at process improvement are
needed in order to maintain better quality that meets a customer’s requirements and also assist
the company to achieve the much required reputation in the market. Well controlled process play
a major role in ensuring the quality costs are reduced, especially the internal, external and
appraisal costs.
2.0 Literature review
In order for an organization to achieve process improvement, it should build a proper team of
professionals and experts in its field. The team will have a duty to recognize problems, analyze,
put forward solutions and make implementations of the best solutions. This should help in
solving problems or take care of the current situation [3]. Process improvement also purposes to
reduce the costs and enable the schedule arrangement of the organization.
In a manufacturing shop floor, all the activities of process improvement do require the use
assisting tools and techniques. The idea of lean manufacturing basically involves improving the
process through waste elimination and cost reduction. Implementation of the KAIZEN concept