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Solving the Injection Mould Breakdown Problem
The Importance of Buy-Off Process and Checklists
Introduction:
Injection moulding is an important process in the manufacturing industry. It is widely used for producing plastic products for various applications like home appliances, automotive components, toys, and many more. However, despite its popularity, the injection moulding process often encounters multiple breakdowns, leading to major losses for manufacturers. According to a recent study, 91% of manufacturers face multiple breakdowns when an injection mould is delivered to their moulding shop.
Problem:
When an injection mould encounters breakdowns, sending it back to the tool maker or repairing it in the factory becomes a major challenge. This results in a loss of customer trust and production supplies, which ultimately results in a major revenue loss. Moreover, the downtime required for the repair or replacement process can be very costly and affect the delivery schedule of the products.
Solution:
The solution to this problem lies in the implementation of a Buy-Off process with its checklists. A Buy-Off process is a crucial step in the injection mould manufacturing process that ensures that the mould is functioning correctly before it is shipped to the customer. The process involves a thorough inspection of the mould and its components to identify and resolve any defects or problems.
The Checklist:
A Buy-Off process must include a comprehensive checklist that covers all aspects of the mould and its components. The checklist should include the following items:
- Core/Cavity Extraction: Ensure that the core and cavity extraction process is functioning correctly and there is no damage to the components.
- Parting Line: Check the detailed parting line to ensure that it is accurate and there are no defects or deformities.
- Angular/Side Core: Ensure that the direction of the angular/side core is correct and there is no damage to the component.
- Gate & Runner Location: Check the location of the gate and runner (hot/cold) to ensure that they are functioning correctly.
- Cooling Circuit: Ensure that the cooling circuit is functioning correctly and there are no defects or problems.
- Ejector Location: Check the location of the ejector to ensure that it is functioning correctly and there is no damage to the component.
- Draft/Undercut Analysis: Ensure that the draft and undercut analysis is accurate and there are no defects or deformities.
- Engraving & Sub-Insert Witness Line: Check the engraving and sub-insert witness line to ensure that they are functioning correctly.