Total Quality Process Control for Injection Molding, 2nd Edition
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1. Total Quality Process Control.
Establishing Process Ownership.
Ideas and Methods.
2. Implementing Total Quality Process Control (TQPC).
Quality Improvement Plan.
Statistical Process Control (SPC).
Controlling the Process.
Cp the Control of Operations.
Cpk-Centered Process Control.
Establishing Company Quality Objectives.
3. Managing for Success, Commitment to Quality.
Objectives for Managing a Quality System.
Proactive Preventive Action.
Total Quality Process Control.
Principles for Quality Systems Engineering.
Objectives for Managing a Quality System.
Customer-Supplier Quality Agreements.
Product Quality Determination.
Form, Fit, and Function (FFF).
Existing Mold Considerations.
Establishment of Responsibility.
Department TQPC Responsibility.
Estimated Piece Part Price.
Assembly and Decorating.
Computer-Integrated Manufacture (CIM).
Control of Operations.
International Organization for Standardization (ISO) Accreditation.
Communicating Quality in Business.
Quality Function Deployment (QFD).
QFD in Operation.
Critical to Quality (CTQ).
Building on TQPC, Product Manufacture.
Failure Mode and Effects Analysis.
Types of FMEAs.
Implementing an FMEA.
4. Customer Satisfaction.
Manufacturing and Supplier Input.
Customer and Supplier Agreements.
Product Preproduction Review.
5. Organization Responsibilities.
Six Sigma Introduction.
TQPC Management Operations.
6. Establishing the Limits for Quality Control.
Preproduction Product Analysis.
Calculation of Plastic Part Cost.
Case Study of Product Cost Analysis.
Estimating Part Cycle Time.
Mold Part Cavity Estimation.
Mold Size Considerations.
Injection Molding Machine Selection.
Molding Machine Screw-type Considerations.
Machine Hourly Rate.
Machine Setup Charges.
Calculating Product Manufacturing Cost.
Material Supplier Limits.
Establishing Manufacturing Limits.
Establishing Total Quality Process Control.
Acceptable Quality Limits.
7. Material Selection and Handling.
Classifying the Polymers.
Product Certifi cation.
Material Specifi cation.
Product Variable Specification.
Incoming Material Testing.
Material Testing Equipment.
Material Safety Data Sheets.
Bar Coding: An Aid in Total Quality Process Control.
Material Handling and Storage.
8. The Mold.
Pre-mold Design Checklist.
Selecting Materials for the Mold.
Cavity Runner Layout.
Runner System Design.
Gating the Part.
Sprues and Nozzles.
Side Core Pulls.
Venting the Cavity.
Positive Cavity Venting.
Mold Connection Types.
9. Manufacturing Equipment.
Electric Injection Molding Machines.
Injection Molding Machine Nomenclature and Operation.
Reciprocating Screw Injection Molding Machine.
The Injection Molding Machine.
Selecting Barrel Heater Conditions.
Mold Fit and Support.
Machine and Mold Clamping Systems.
Maintenance of Machinery.
10. Auxiliary Equipment.
Material Feeders and Blenders.
Material Feed to the Injection Molding Machine.
Material Blending at the Hopper.
Blending Quality Checks.
Color Concentrate Blending.
Plant Equipment Cooling Systems.
Granulators or Grinders.
Part Removal, Conveyor Systems, and Robots.
Quality Inspection Equipment.
Quick Mold Change.
Production Startup for Process Control.
Acceptable Quality Level Limits.
The Injection Molding Process.
Injection Molding Startup.
Other Molding Variables.
Fine Tuning the Cycle.
Regrind Effects on Part Quality.
Determining the Missing Variable.
Process Control Charting.
Maintaining Process Control.
Solutions to Typical Molding Problems.
Controlling and Monitoring Process Variables.
Process Line Integration.
12. Part Testing at the Machine.
Selecting the Test.
Verifying Molding Conditions.
Testing of Plated Parts.
Post-Mold Shrinkage Testing.
13. Part Handling and Packaging.
Part Handling and Packaging.
Automatic Part Packaging.
14. Part Design Influence.
Selecting the Correct Design Parameters.
Part Design for End-Use Applications.
15. Assembly Techniques.
Plan for Assembly.
16. Decorating Considerations.
Control of the Process.
Spray and Wipe.
17. Customer and Employee Satisfaction.
Appendix A. Quality Management System (QMS) Control of Documents Procedure.
Appendix B. Design of Experiments (DOE): Statistical Troubleshooting Process Screening for Reducing the Number of Variables.
Appendix C. Checklists.
Appendix D. Supplier Evaluation Survey.
Appendix E. Mold Problem Solutions.
Appendix F. Decoration & Information Solutions.