In the existing injection molding industry are faced with:
Raw material increase
Labor costs have skyrocketed
Difficulty in recruiting staff
Large turnover of personnel
Product price decline
The problem of increasingly fierce competition in the industry.
I
njection molding industry has entered the era of transformation, small profit and reshuffle, injection molding workshop management needs to establish a “scientific, perfect, systematic, standardized” operation management system, so that “everything is managed, everyone is in charge” of the working atmosphere of the department, for the injection molding workshop each post work efficiency improvement, manpower reduction has the following measures and suggestions:
First, the upper and lower mold workers to improve work efficiency, reduce manpower measures
1. Do a good job in the production planning arrangement to reduce the number of machine replacement due to improper scheduling.
2. Reasonably set the number of thimble and ejection length to reduce the frequency of broken pins in production.
3. To strengthen the process of production mold cleaning, lubrication, the bartender work, reduce the mold failure rate.
4. Strictly control the phenomenon of die pressing in the process of injection molding and reduce the number of die falling maintenance.
5. Use appropriate tools to take the adhesive parts of the mold, prevent the mold from being injured by careless operation, and reduce the number of mold maintenance.
6. Make the upper and lower mold tool car and the hanging ring waiting equipment positioning storage area, reduce the time to find the upper mold tools.
7. Promote the “fast mold up method” to refine every action of the upper and lower molds and convert internal time into external time.
8. Reduce the clamping force and open locking speed to reduce mold deformation and impact.
9. The mold channel entrance is designed as a sinking hole, and quick joint is used to reduce the time of disassembling and assembling the water nozzle.
2. Measures to improve work efficiency and reduce manpower for mold testers
By improving the level of mold designers, improving the working quality and efficiency of mold testers, and reducing the workload of mold testers, the purpose of reducing mold testers is achieved:
1. Engaged in mold design with mold flow analysis software, optimized mold structure, improved mold runner, gate, cooling, exhaust, demoulding and other effects.
2. Reduce the increase of mold modification, mold repair and mold test caused by mold structure problems
3. Conduct injection molding technology training for mold designers, and give full consideration to material properties, injection molding process requirements and injection molding quality requirements when designing molds
4. Provide injection molding training to mold testers, improve their ability to find, analyze and deal with problems, improve the quality and efficiency of mold testing, and reduce the number of mold testing.
5. Specify the number of new mold test (no more than 3 times)
6. Do a good job of preparation before mold test, choose the appropriate injection molding machine, scientific mold test to shorten the time of mold test, reduce the test modulus.
7. Formulate the process of mold trial, standardize the requirements of mold trial, clarify the purpose of mold trial, increase the responsibility of all departments, and reduce the number of invalid mold trial from the management.
8. Select experienced, professional and responsible personnel for mold trial, shorten the time of mold trial and increase the number of mold sets.
Measures to improve work efficiency and reduce manpower for the personnel of the aircraft transfer
1. Implement automatic and unmanned injection molding to reduce the adjustment caused by the instability of manual boot.
2. Control the ambient temperature of the workshop to achieve the purpose of stable mold temperature, material temperature and injection molding process conditions. (ring)
3. Formulate standard process conditions, arrange production machines reasonably, and ensure the repetition of process conditions. (law)
4. Strengthen the injection process management, prohibit the injection process operators, mold workers, feeding. Staff and other non-technical personnel adjust the machine to prevent process fluctuations and changes in the quality of rubber parts. (people)
5. To do a good job of guaranteed injection molding machine, to ensure that the repeat precision of injection molding machine and the stability and reliability of the process conditions. (machine)
6. Filter the cooling water to prevent the mold temperature change caused by the rusting of the water channel system resulting in abnormal quality. (machine)
7. Strictly control the quality of raw materials, water inlet materials and pumping granular materials. Water inlet materials need to be recycled after dust screening to prevent the adjustment caused by raw material problems. (material)
8. The preventive maintenance, the use of injection mold, work, reduce the die failure and rotary die after the fixed mold, machine work. Use special paper to clean the oil on the mold before the mold testing machine, reduce the time of mold testing and save materials.
9. Conduct comprehensive and systematic training of injection molding technical personnel, master the knowledge of material, machine, mold, process and defect analysis, improve their ability to analyze and deal with problems, improve their injection molding technical level and control ability of injection molding process, reduce blind machine adjustment, and take the road of scientific injection molding.
10. For special moulds (such as multi-neutron moulds), precautions should be marked on the moulds to make problems obvious and prevent personnel from making mistakes.
11. The pipe should be cleaned before the shutdown and then cooled, to prevent the material from burning the screw can not be cleaned, use the screw cleaning agent to save the time of cleaning the pipe.
Iv. Measures for ingredients to improve work efficiency and reduce manpower
1. The batching room needs to increase the number of mixer (mixer), the color and the type of plastic material ingredients, equipped with enough and appropriate tools to clean the mixer, improve the efficiency of cleaning the mixer, shorten or reduce the time and workload of cleaning the mixer.
2. If the mixer is more, a variety of materials can be mixed at the same time to reduce the number of ingredients.
3. Change the traditional way of batching by shift, implement single batching, make raw material rack, complete the materials required by the order in one time, reduce the time and workload of cleaning mixer.
4. Do a good job in the ingredients plan and make the ingredients board to prevent the phenomenon of wrong materials and multiple materials. Materials before and after ingredients should be clearly marked to reduce the amount of ingredients by reducing the occurrence of problems.
5. Conduct training for batching staff to improve their working ability, quality and efficiency, so as to achieve the purpose of reducing staff.
6. Use color master, color master proportional valve, edge crusher and central feeding system to cancel the batching link and reduce batching staff.
7. The number of batching staff in one class can be reduced by changing the concept of batching, improving the efficiency of batching, doing well the label of batching and implementing single shift batching.
Five. Feeding staff to improve work efficiency, reduce manpower measures
1. Make suitable feeding ladder to facilitate feeding and improve feeding efficiency.
2. Place the materials to be filled in the designated area according to the machine, and the materials of each machine shall be clearly marked. So as not to add the wrong ingredients.
3. Use edge automatic suction machine instead of manual feeding.
4. Adopt central feeding system and color master proportional valve to realize automatic feeding.
5. Improve the filling bucket and reduce the feeding frequency to reduce the feeding personnel.
Vi. Measures to improve work efficiency and reduce manpower for crushing staff
1. The crusher shall be added to the crusher room, and the crusher shall be divided according to the type and color of raw materials to reduce the workload of cleaning the crusher.
2. Make the rubber box bracket, reduce the time for the crusher to take the water outlet and reduce the labor intensity.
3. Use the automatic transmission belt crusher to reduce the workload of the crusher (one person can use two of the same crusher).
4. Isolate the area where the crusher is placed to avoid cross contamination. Strictly control the purity of the nozzle material, reduce the time for the crusher to clean the foreign matter in the nozzle material.
5. By improving mold quality, injection molding technology and management level, controlling defective products and water inlet material quantity, reducing the workload of crusher.
6. The mold adopts hot runner system to reduce the water inlet material and the amount of broken material.
7. The edge crusher is used to realize automatic and unmanned crushing.
8. When the crusher is out of service, cover with dust cover to reduce the workload of cleaning the crusher.
9. Train shatterers to improve their work quality, efficiency and responsibility, so as to reduce the number of shatterers.
7. Measures for injection molding machine operators to improve work efficiency and reduce manpower
1. Use manipulator and conveyor belt instead of hand to take out products and water orifice, realize automatic and unmanned operation production, reduce manual boot.
2. Must be prepared to injection mold cleaning, lubrication, protection, prevent the thimble, slider, guide pin, guide sleeve, wear and tear, caused flash products. Do a good job of cleaning the rubber chips, rubber silk, oil and dust on the molding surface to reduce the rough edges around the products caused by the damage and pressing of the parting surface. Bartender (mould)
3. Adopt in-mold shear gate technology or change the direct feeding mode to point gate to reduce the time of cutting water gate. (Mold design)
4. Improve the steel of the mold, improve the rigidity and hardness of the mold, and the mold should add the brace head, reduce the raw edge of the product caused by the mold compression deformation. Wear resistant steel is used for mold gate position, slider and moving parts and special treatment is carried out to reduce the burring caused by excessive wear of these parts. (Material of mold)
5. Do a good job of mold testing, thoroughly improve mold problems, improve mold quality, set technological conditions scientifically, and prevent products and water mouth from sticking mold phenomenon.
6. Optimize the layout of the machine in the injection molding workshop, so that one operator can simultaneously see the processing of two or more injection molding machine products. Improve the working efficiency of operators, to achieve workshop automation, unmanned operation production.
7. Do a good job in injection molding machine maintenance insurance prevent machine hinge, elder brother Lin Zhu wear, clamping precision injection molded parts caused by poor raw edges. (Maintenance of machine)
8. Reduce mold locking force to prevent mold deformation caused by excessive mold locking force and rough edges. Scientific setting of opening and closing mold parameters, reduce the speed of opening and closing mold, reasonable setting of low pressure protection parameters, to prevent the rough edge caused by mold collision. (Setting of process)
9. Use appropriate tools for gate and raw edge processing, improve processing tools and techniques, improve processing efficiency and quality, and reduce machining manpower.
10. Make clear the processing parts, processing standards, processing requirements and processing methods of products, reduce unnecessary processing actions and shorten post-processing time. For the internal plastic parts, do not affect the function, size and assembly effect of the raw edge does not need to be processed, reduce the processing amount. And adhere to the principle of not allowing the production of flying edge mold.
11. Improve the salary of operators (slightly higher than the salary standard of peers), reduce the loss of operators, stabilize the staff team, the use of skilled workers boot (a skilled worker can be up to 2 skilled workers), is also one of the methods to reduce the airport manpower to improve the working efficiency of operators.
12. Strengthen job training for operators, improve their work quality, work efficiency and work responsibility, and mobilize the enthusiasm of employees.
Eight. IPQC measures to improve work efficiency and reduce manpower
1. Clear product quality standards (size, appearance, material, assembly, color…) And focus on the abnormal points of customer complaints and returns, and do a good job of the “first inspection record form” of products. Only after the first inspection is confirmed OK, can it be put into mass production.
2. Change the concept of “post-inspection”, strengthen the process control, for plastic parts prone to change parts (thimble, parting surface, pinhole…) And the time when quality is easy to change (meal time, shift time…) Focus on monitoring, try to stabilize the quality of injection parts, in order to reduce or eliminate IPQC personnel.
3. Establish the idea that “the quality of plastic products is from injection molding, not from seeing”, that is to say, “quality products are designed, manufactured, managed and controlled, rather than tested out”.
4. Implement scientific injection molding, gradually realize automatic and unmanned production mode, prevent quality fluctuations and adverse defects in the process of injection molding, so as to achieve the quality state of product quality without IPQC.
Ix. Measures for mold repair personnel to improve work efficiency and reduce manpower
1. To strengthen the use and maintenance of injection mold, the bartender work, reduce the die failure rate, reduce the modulus. Strengthen the mold rust prevention work, reduce the occurrence of mold rust phenomenon.
2. Use appropriate mold steel (corrosion resistance, wear resistance, pressure resistance), and ensure that the mold has enough steel and hardness, prolong the service life of the mold.
3. The moving parts of the mold (vulnerable workpiece) are made into inserts, wear-resistant steel is used and quenched to facilitate quick maintenance and increase service life.
4. Reasonable setting of thimble times and thimble stroke (on the basis of the smooth release of the product, more than one top). And to do a good job of cleaning, lubricating, protecting thimble, thimble way to avoid empty change traditional thimble mode, prevent burning needle, needle breakage phenomenon.
5. Enhance the protection consciousness of the mold, prohibit the phenomenon of “die pressing”, and reasonably set low-voltage protection parameters, and install “mold monitoring and protection device” if necessary for special molds.
6. The mold nozzle adopts the wire-drawing structure to prevent foreign bodies such as wire drawing and mold surface viscose chips and dust during the injection production process, which should be cleaned in time to avoid damaging the mold.
7. Install the thimble spring on all molds. If there is fracture, it should be replaced immediately to avoid the phenomenon of needle burning and broken caused by the imbalance of ejection.
8. There should be a certain amount of spare parts of the mould that are prone to loss and multiple failure parts, so that when the above parts of the mould fail, they can be replaced in time, so as to shorten the time of mould repair and reduce the manpower of mould repair.
9. Reduce the clamping force of injection molding machine (each machine should be controlled below 100) and the speed of unended closing mold to prevent mold deformation and collision.
10. Measures to improve work efficiency and reduce manpower for machine repair personnel
1. Change the idea for the maintenance of equipment is broke by the ex post maintenance into prevention concept. (preventive bao and predictive difference).
2. Make the injection molding machine use, maintenance, security rules, and arrange the specialist injection molding machine and peripheral equipment
