Total Quality Process Control for Injection Molding, 2nd Edition
In the same simple, easy-to-understand language that marked the first edition, Total Quality Process Control for Injection Molding, Second Edition lays out a successful plan for producing superior plastic parts using high-quality controls. This updated edition is the first of its kind to zero in on every phase of the injection molding process, the most commonly used plastics manufacturing method, with an all-inclusive strategy for excellence. Beginning with sales and marketing, then moving forward to cover finance, purchasing, design, tooling, manufacturing, assembly, decorating, and shipping, the book thoroughly covers each stage to illustrate how elevated standards across individual departments relate to result in the creation of a top-notch product. This Second Edition:
Details ways to improve plastic part design and quality
Includes material and process control procedures to monitor quality through the entire manufacturing system
Offers detailed information on machinery and equipment and the implementation of quality assurance methods—content that is lacking in similar books
Provides problem-analysis techniques and troubleshooting procedures
Includes updates that cover Six Sigma, ISO 9000, and TS 16949, which are all critical for quality control; computer-guided process control techniques; and lean manufacturing methods
With proven ways to problem-solve, increase performance, and ensure customer satis-faction, this valuable guide offers the vital information today's managers need to plan and implement quality process control—and produce plastic parts that not only meet, but surpass expectations.
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.
"In the same simple, easy-to-understand language that marked the first edition, Total Quality Process Control for Injection Molding, Second Edition lays out a successful plan for producing superior plastic parts using high-quality controls". (Daily Finance, 14 December 2010)