Systematic Molding I

O 2008 RJG, Inc.

Copy written Material

Do Not Duplicate without the
express written consent of
RJG, Inc.
Inasmuch as RJG, Inc. has no control over the use to which others may put this material, it does not
guarantee that the same results as those described herein will be obtained. Nor does RJG, Inc.
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of the material or design or both should make his own tests to determine the suitability of the
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Designed and developed by RJG, Inc. Manual design, format and structure copyright 2006, RJG,
Inc. Content documentation copyright 2006 RJG, Inc. All rights resewed. Material contained
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Table of Contents

Introduction ....................................................................................................... 1-4

Cornerstones of Successful Molding Programs .....................................................
1-10
Part Design .............................................................................................
1-12
Material ..................................................................................................1-21
The Mold .................................................................................................1-44
The Process ............................................................................................1.62
Machine Safety ..................................................................................................1-78
Injection Molding Economics ............................................................................... 1-81
The Molding Problem Simply Stated..................................................................... 1-90
Molding From the Plastics Point of View .............................................................. 1-104
Getting Started................................................................................................. 1-105
Plastic Temperature................................................................................ 1-107
Plastic Flow ........................................................................................... 1.1 24
Plastic Pressure .................................................................................... 1.141
Cooling Rate and Time............................................................................ 1.154
Instrumentation................................................................................................ 1.168
Implementation Strategies................................................................................. 1.183
Introduction to Decoupled 111 Molding................................................................ 1-188

3 .Sys l
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The RJG, Inc. Mission is...

Helping Molders Succeed

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We Make Our Customers

More Competitive By:

Giving them the ability to ship

ONLY GOOD PARTS
to their customers and
minimize the number of
abnormal parts produced.

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A

Overview of the Process

I. Plastic pellets are gravity fed from a hopper into a heated pipe called the barrel

;
. The plastic is moved forward, melted and mixed by a rotating screw in the barrel
until a measured amount accumulates in front of the screw

i. A precise amount of the melted plastic is then injected into a mold where it is
shaped and cooled

k Additional melted plastic is then pushed into the mold to compensate for plastic
shrinkage during cooling

After plastic freezes across the entrance to the mold cavity, called the gate,
additional cooling of the part is necessary

';. While this cooling is occurring, plastic is being prepared for the next part

ij The hardened plastic is then removed from the mold, and a new cycle begins

How many variables are there in this process?

6-Sy~l
 Injection molding is a conversion process
Raw material is converted into a finished part.
The properties of the final part are determined by what was done to the plastic to convert it:
-
Heat Flow - Pressurize - Cool
By looking at the process from the viewpoint of the plastic rather than from outside the
machine, the variables can be reduced to:
> Plastic Temperature

ii Plastic Flow Rate

';i Plastic Pressure Gradient

,/-'
[Q E +PRESSURE
\r\ PACK&HOLD
L.... >

3 Plastic Cooling Rate and Time COOLING

RATE & TlME
This strategy will Help Molders Succeed 7-SWI
Cornerstones of Successful
Molding Programs
 @
Successful molding programs occur when an understanding of the whole
process from part design through finished part is promoted.

Focus on understanding the role of:

I;; Part Design
I
> Material
3 Mold Design & Construction
3 The Process

What are your part design issues?

What are your plastic material issues?

What are your mold issues?

How are they being addressed?

 %
A successful injection molded plastic product starts **v-

with a good part design

:i- A plastic part design has two basic requirements:

Functionality (structural, aesthetic, etc.)
Manufacturability

> Those two requirements are often in conflict with each other

;; A successful product, therefore, is usually the result of a series of compromises

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13 sys l
ii There are some guidelines based on knowledge of plastic injection molding that
can aid in the design to production process

i. All plastic parts, no matter how complex, share three basic design elements:
The wall of the part, which defines the shape
Additions to the wall
= Subtractions from the wall

The design guidelines for these three elements fall into four categories:
Nominal wall
Radius
Part Release
Additions/Subtractions
14-Sysl
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If the functional requirements of a part require a departure from nominal
wall, the designer must visualize how plastic flow and shrinkage will
interact with the design to affect properties.
PLASTIC FLOW

POOR SHARP
TRANSITION

PLASTIC FLOW

BETTER GRADUAL
TRANSITION

BEST SMOOTH
TRANSITION

2. Wall thickness changes should be minimal and gradual

As a general guideline, wall thickness changes should be less than 25% of
the nominal. This is more important with semi-crystalline plastics
+ Lack of uniform nominal wall thickness is the single most troublesome
problem encountered relative to part design
15-Spl
 -I

As plastic flows into the

cavity, it finds the thick
sections on the Ranges
> One of the most common presents less resistance.
Tn
hn
e
io
,t, the thinner I I ,I

problems that can occur as center section slowsdown. ; 1

'-----------------------
,
I

a result of wall thickness :------------------------------:

variations is backfilling or
"racetracking", which can
create a dead spot in the ~n;g~;g~;~~;a~~
the flanges until the two fronts
Part meet and form a knit. The air
that is in front of the melt is , I

Example: pushed to the center of the

pa*
Concave lenses, parts with
flanges, glue or weld joints

As plastic is pushed into the

cavity to complete filling of the
pa* the air is now being
compressed, which causes a
dieseling effect. The plastic is : D

ignited and a burn oaurs.

I

16-Sysl
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PARTRELEASE
As plastic parts cool and shrink in the mold they:
i Pull away from the cavity
9 Draw down tightly onto the core
Since the part must slide out of the mold without distortion, draft angles parallel to part
release are necessary on all draw surfaces.

The degree of draft required is a function of:

i Material shrinkage rate and abrasiveness Die-Draw
ii Part surface requirements
> Uniformity of wall thickness
> Depth of draw
Any draft is better than none.
Specify the largest that the functional requirements of the part will allow,.SysI
 C
ADDITIONS & SUBTRACTIONS
3 Additions are part features that present a non-linear extension of the wall

- Ribs
Bosses
Gussets
r-

Raised areas
i- All have much in common from a design point of view
k The design issues relate to:
Shape
Spacing

t
T 112T
w
1 /- t
T
1 1
SHAPE
The primary goal is to reduce the effect of modifying the constant wall thickness
by keeping the base as small as possible
H Generally, around 112 the wall thickness (50% of the wall thickness) 19 - SYS I
 @2

Essential information to be agreed upon by the

Product Designer and the Mold Designer:

1. Parting line location

2. Gate location(s)
3. Ejector pin locations
4. Coolant line size and locations
5. Surface finish
6. Radius -- where and how much
7. Draft -- where and how much
8. Tolerances and their relationship to reality

20 - sys l
 t
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Material selection is part of the design process and can directly cause failure

A key element in a successful plastic part program is the selection of the

appropriate material for the application.

The process of material selection is complicated by the fact that there are literally
thousands of polymers, blends, alloys, and compounds available.

The selection process can be simplified by comprehending:

9 The performance requirements of the part
'r How materials are classified
i. Testing methods -
22 SYS I
 -2

Polymer:
;
. From the Greek Poly meaning many, and Meros (mer), meaning part(s)

Chemical Composition: Example

'i. Polyethylene: Crack crude oil to ethylene then polymerized (linked together)
to form 500-1,000,000 ethylene units

Key Points:

Polymers can have the same carbon backbone but drastically different properties

i; Polymers with Oxygen (0),Nitrogen (N), Chlorine (CI), Bromine (Br), or Fluorine
(F) probably have to be dried

Time and space do not allow us to review each polymer composition and its
properties. An excellent source for basic polymer descriptions can be found
in the first pages of the yearly Modern Plastics Encyclopedia.
 8
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Chain Lengths
;
i At room temperature
CI = Methane, a gas
Cci = Hexane, a liquid
'17 = Kerosene

- '50 = Wax
C5,~,,ooo,ooo = Polyethylene

For strength
-,

> Long molecules are preferred

For processability
;
-
. Short molecules are preferred
Easy flow
Low viscosity
Transmits pressure more hydrostatically
>
-
Long molecules
Difficult to flow
High viscosity

-
> Viscosity changes dramatically with changes in flow rate
Dynamic: flow rate during filling
Static: flow rate during pack and hold
Large static pressure losses along the flow path
Resin manufacturing must compromise/balancechain length vs. strength vs. flow.
Most polymers that find commercial use as plastics or rubbers have molecular weights 24 - Sys I
between 10,000 and 1,000,000.
 C
-.* "

Batch to Batch Variations Cause Changes in Viscosity

> Effects of Molecular Weight

Generally as molecular weight increases, physical properties increase
at the expense of processing ease
Short chains - easy flow
Long chains - difficult to flow

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27 Sys I
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Molecular Architecture of Individual Chains:
i; Linear streamlined

> Branched
Low density polyethylene (LDPE)

ii Linear non-streamlined
Polycarbonate
M, 30,000 vs. 320,000

28-Sy~l
a 5
cn
z cn
.-'
CI
a m
c
3 1
a
cn
I
 --
ABS Acrylonitrile, Butadiene, Styrene - Terpolymer

3 Tougher than polystyrene homopolymer

+ Higher heat, more rigid than butadiene
ii Tougher than SAN copolymer
% Better chemical resistance than HIPS copolymer

ACRYLONITRILE

BUTADIENE STYRENE 30-WI

 -I
Polymer Chain Degradation

> Polymer chains are strong

Aramide fibers (flack jackets, tires)

> Chains can be broken by improper processing

Too much heat

- Too much time at elevated temperatures (drying and melt)

Too much shear force
Presence of a chain-breaking chemical (e.g., water)
J Polyester

J Polycarbonate

J Nylon

;i. Proper drying is essential for these materials

31 - SYSl
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Degradation

:i Improper processing can degrade polymer chains and provide

poor part performance
3 Chain degradation will provide a regrind that is easier flowing
(lower viscosity)
9 Shorter molecules = poor strength

IHow can this be detected? 1

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32 S ~ lS
 Polymers - Plastics
--3

Plastics = Polymer + Additives

Additives:

3 Impact modifiers (rubber) 3 Plasticizers

?;. Fillers % Fiber reinforcements
> Nucleating agents > Heat stabilizers
> Flame retardants > Lubricants
> Mold release agents + Antistatic agents
> Antioxidants ii Coloring agents
> Wetting agents > Slip aids

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33 sys I
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Additive Degradation:

i Additive chain size is small relative to the polymer

k May become volatile during processing which can
result in:
Accumulation in vents, mold surfaces, etc.
Change in physical properties (often an
increase)
Stiffer flow (higher viscosity plastic)

Change in Additive Content is a Prime Difference

Between Virgin and Early Generations of Regrind.

Material is going to vary folks -

that's no excuse!
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34 sys l
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Thermoplastics vs. Thermosets

Characteristics Characteristics

r Softens when heated; 2 Hardens (cross-links) when

hardens when cooled heated
i Can be re-softened 'r Cannot be re-softened
r Limited use at higher T Excellent high temperature

temperatures properties

Our focus is on thermoplastics 35-Sysl

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Polymer Morphology

Two families of thermoplastics

Amorphous Semi-crystalline
i Random Structure r Ordered Structure
i- Broad Melting Point h Sharp Melting Point
5- Often Solvent Sensitive P Solvent Resistant
k Poor Fatiguelwear r. Excellent Fatigue Wear
5- Low Shrink r. High Shrink
>- No Molecular Cuddling k High Molecular Cuddling
> More Forgiving on dimensional i Problematic on
Control dimensional Control

36 -SF l
 List of Common Amorphous Resins

I;;ABS
> Polystyrene
>i High Impact Polystyrene
k Polycarbonate
> PCIABS Blends
ii Thermoplastic Urethanes
+ Polyvinylchloride
> Modified Polyphenylene Oxide
List of Common Semi-crystalline Resins
i; Acetals
+ Nylons
Polyesters (PET, PBT, PETG)
+ Polyethylenes
+ Polyproplyenes
v Polyetheretherketones (PEEK)
37 - Sys l
 --Bl

for semi-crystalline polymers, cooling rate

takes on greater significance that should be
dealt with in early design stages.

ii Dimensions vary significantly with cooling

rate in semi-crystalline parts

38-SpI
 Problems:

3 Requires complex blending equipment

T;. Hard to do batch control
'P Older and riper mixture

i;. Never purges contaminants

3 Colors get darker
i;. Impossible to test worst case
 (Unless it is contaminated)

Regrind Data for Injection Molded Styron 6,000 Series Resins

~ypical'Properties Solid injection Moldings

Virgin
100% Regrind
Material

F~rstPass Second Pass Third Pass Fourth Pass Flfth Pass

Tensile Yield (psi) 3,860 3,830 3,870 3,900 4,010 4,000.00

Tensile Rupture (psi) 3,350 3,400 3,385 3,480 3,450 3,440.00

Elongation (%) 26 34 32 36 36 36.00

Notched lzod (ft Ibslin) 1.61 1.61 1.62 1.63 1.64 1.60

Tensile Modulus 327.000 332,000 324,000 329,000 337,000 343,000.00

Typical property values; not to be construed as specifications

Source: Dow Chemical Co. 43 - Sys I
 MOLD DESIGN GUIDELINES

2. Provide flow path from the machine to the cavities

3. Allow air to escape from the cavities
4. Cool the plastic part
5. Release the part

Mold design guidelines for robust processing are centered around

these five functions
45 - Sys l
Line of Draw
Projections or holes that are
features of a part may make it
impossible to-open the mold
or eject the part straight off
the mold. Internal or external
undercuts perpendicular to the
angle of mold opening or
ejection are not in line of
draw.
Molds that form parts with
features not in line of draw
must have a means of moving
the undercut away before the
mold opens or the part is
ejected.
This is done by using movable
cores or pins called slides.
Moving of the slides is
typically done with the use of
cylinders, lifters, or angle pins.
 %
-

The cavity in a mold defines the shape of the part

The mold is a mirror image of the part:

The cavity half of the mold defines the core side of the part
The core half of the mold defines the cavity side of the part
;Mold cavities can be:
Single
Multiple
Family
i No mold can be more capable than a single cavity, single gated mold

the time and at

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49 sys I
 9
Sprues and Runners

> The sprue bushing is the feed opening that connects the machine nozzle to
the mold

k The solidified plastic piece that is formed in the bushing is called the sprue

k The sprue is tapered with the narrow end where the nozzle meets the sprue
bushing
The draft for this taper should be at least two degrees

The bushing should be highly draw polished. (in direction of flow)

L The wide end of the sprue should have a sprue puller

This is a shortened ejector pin that is undercut

"2" Puller

50 - Sys I
 h;

The taper, polish, and puller assure that the sprue will be pulled out of the
fixed half of the mold when the mold is opened. The puller pin can then be
advanced to eject the sprue off the moving half of the mold.
The sprue puller also serves as a cold slug well.

Undercut
R~ng

Reverse
Taper

"Z"Puller

51 - Sys l
Can Be Heated = Hot Sprue Bushing
 -6
P To get plastic from the sprue
to the cavity(s), channels are
machined in the mold. These
channels are called runners.
The common runner shapes Half Round Trapezoidal
(preferred) (Compromise)
are:

> A well designed cavity and

runner layout will allow for a
naturally balanced flow of
plastic to each cavity

'i. If the runner area and flow

length are not the same the
runner is imbalanced
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52 Sys 1
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If the mold does not treat the plastic material the same in each
cavity. This fact may render the process uncontrollable.

- - Size
This is why no mold can be more controllable than a single
cavity mold.
53 - sys l
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Hot Runner Manifold System - 2 Drops

The runner can be kept liquefied through the use of a hot runner manifold.

Nozzle Tip
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54 Sys l
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w
*

A small channel is machined in the mold to connect the runner to the

cavity.

-33 TOP VIEW

GATES
;

ix
- 1
! I TOP VIEW

1j
a TOP VlEW

+b
L K
-- ---P
SIDE VIEW SIDE VIEW SIDE VIEW

EDGE GATE SUB GATE SPRUEGATE :

+
_._..____,_________------------------------
________.__________--..-..- 4-----...--.---.....----.-.---..----

- TOP VIEW

SlDE VlEW

FAN GATE
j -1
TOP VIEW

SlDE VlEW

FLASHGATE
j
i
e
TOP VIEW

SlDE VlEW

RING GATE
3 4 g

This small channel is called the gate. There are many different gate
designs: 55 - SYS I
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SIZING THE GATE(S)
-,

3 Small enough to facilitate freeze-off and separation

';. Big enough to minimize pressure loss
Depth (d)
\;. A gate has three critical dimensions: depth, width, and land

Sizing Guidelines:
Material
> Depth
Determines gate freeze time and should be 40% to 60% of the part's nominal wall
J Affects jetting and orientation
> Width
Affects orientation and jetting and should generally be one to three times the depth
dimension
3
-
Land
Should generally be one-half of the depth dimension, but not exceed 0.030
A short land length may cause long gate seal times --- why?
56 - SYSl
GATE SIZE MUST BE THE SAME FOR ALL CAVITIES!
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--
Heated systems require the use of a valve gate to seal the gate.
Of critical importance is the number of gates and their location.

Open

Closed

What is the primary reason for using a valve gate? 57-SysI

 -I
A closed mold is full of air. As plastic is injected into the mold the
air must have an escape route. A small channel or hole is machined
in the mold called a vent.

Vents Can Be:

P Edge vents
9 Venting channels
Venting pins
P Vacuum venting

Vents are in reality a reverse gate. They tend to be the most

overlooked and neglected item on a mold.

There are never too many properly designed vents in a mold. 59-sy.1
 E
The critical dimension on a vent is the depth.

-
25 'NIDE VENT

Vent Vent

0 rX)5 - 0010' DEEP X 0 250.0 50J"WlDE -VENT RELIEF

VENT DIMENSIONING

0 0005.0 001" CLEARANCE

ON EJECTOR OR CORE
AT MOLD FACE PINS FOR VENT

60 - Sys l
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Mold Design Considerations for Robust Processing
Treat Each Cavity the Same Design a Mold Which Will Make a Part to
Tolerance
';. Plastic flow length
r; Cooling ijUse correct shrinkage data
> Gate positions P Seal the gate
Wall thickness 3 Provide adequate draft for part release

Design a Mold Which Can Easily Design a Mold for Cycle Time
Be Filled
> Use proven, adequate ejector system
ijBalanced = Always get the part(s) out - one
> No excessive flow lengths ejection cycle is most effective
9 Constant wall thickness
3 Use software tools to estimate 9 Use adequate cooling, which is the same
pressure losses in the mold for each cavity
= Place cooling where heat is
concentrated
= Allow for flow monitoring on all
channels
';. Use correct Diameter/Distance/Pitch
 A.

The Molding System

There are three major components

in Injection Molding Dryer (optional)
Loader (optional)

';i. The Mold

> A hydraulic system or servo drive mechanism

> A control system
What are the tasks of each component?
Mold
Injection unit
Clamp -SPI
 &%
The Injection Unit

Parts with very complex geometries can be produced by

the injection molding process because:
Plastic melts/softens when heated
> The melt can be made to flow into a mold and formed
> The effect of shrinkage can be minimized with pressure

The Injection Unit has the tasks of:

b Preparing the plastic (Hearnix)
+ Flow the plastic (Injection)
b Pressurizing/Depressurizing plastic (PacWHold/Decompression)

What are the major components of the injection unit?

54 - sys l
 . -$3
Installed at the metering end of most screws is the non-return valve
> Purpose of the valve is to prevent plastic from backflowing over the screw flights during
injection
3 Even though there are many different designs, they all fall basically into three
categories:

-
.-, ..-
...................
- - -- . . .. .......

ts

Ring

Poppet

Ring

What characteristic do they all have in common?

How does the injection unit cause plastic to flow? 65 - SYS I
 P
Controls
The significant injection unit controls are those that effect the tasks:
Prepare the plastic
2 Temperatures (feed throat, barrel, nozzle)
P Screw rotation speed (r.p.m.)
i- Back pressure (in plastic)
i Screw back position (shot size)

Flow the plastic (first stage)

P Pressure(s) (boost, high, first stage, etc.) 1
,Position(s) (screw speed changes) jt, F - /

i Speed(s) (forward screw movement(s)

u Time(s) (fill and/or total injection)
i- Velocity to pressure transfer (position, time, injection psi, cavity psi, cavity psilexternal)

Pressurizing the plastic (second stage)

i Pressure(s) (pack, hold, low, etc.)
v Speed(s) ( pack speed, velocity, volume, etc.)
i. Timer(s) -
66 sys I
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Mold Deflections
Hydraulic and toggle machines support the mold differently

How well the mold is supported depends on three things

> Type of clamp
Hydraulic
Toggle

Stiffness of the platens

> Cast - Stiffer
i Plate - Easier to bend

Size of the mold relative to the platen size

i j Must cover 213 of the space in either direction minimum
May be less for some machines
i; Supports differently if the mold projects beyond the tie bars
70-Sys I
 @
Fundamental Hydraulic Concepts

Pumps provide flow

> Flow into an actuator translates to movement
Cylinder = linear movement
Motor = rotary movement
';. Flow and pressure cannot be controlled independently
ii To set control flow using a flow or speed control, there must be an
abundance of set pressure (potential energy) to overcome the resistance
to flow or to load
i. When controlling a set pressure on the load, such as during pack and
hold, there must be sufficient flow from the pumps over the relief valve to
dump excess flow to tank
> To maintain control of the process, flow and pressure must be controlled
at the appropriate times

72 - Sys l
 -B
Blaise Pascal developed the equation for pressure:
Force = pressure times area
Area = force divided by pressure
Pressure = force divided by area F=PxA
F
A= -
Three hydraulic principles: P
Movement is caused by flow P= -
F
Rate of flow determines speed A
Load (resistance) determines pressure

A pump makes oil flow, but there must be resistance to flow to create pressure.
We cause things to move in the injection molding process, including plastic, by
controlling oil flow, not pressure.
It is not the pressure required to move the plastic, it is the pressure that results from moving the
plastic.

Pressure can provide information about the process.

In order to do that, we must understand how to instrument the process, collect data, and
interpret that data to make it useful information.
73 - Sys l
 .@-"
Force can be intensified in a hydraulic system.
The determining factor for force intensification is the square inch area on which the
hydraulic pressure is applied
4 If the piston in a cylinder has more area than the area where the force is being applied then
the output force will be greater than the input force

Pressure increases inversely proportional to the area ratios.

FORCE = PRESSURE x AREA

(Ibs) (psi,,) (h2)

> For example, if two pistons of different size are connected by a rod, the pressure existing
on the smaller area will always be greater
This principle also applies to the cap side and the rod side of a normal double
acting piston
74-SpI
 BB
Intensification of Force is in Effect in the

lntensification Ratio: R,
'i The ratio of the cross sectional area of the hydraulic cylinders on the injection

Fq
unit t o the cross sectional area of the check ring or screw

A, = Cross sectional area of the hydraulic cylinder

A, = Cross sectional area of the closed check ring on the
end of the screw
. Determines pressure amplification factor between hydraulic cylinder pressure
;
and plastic pressure
'i Determines fill pressure of plastic
;
i Determines pack pressure of plastic
;
i Determines back pressure of plastic
-
'i Used to be 10:1 on most machines or so we thought
;
i Now varies on new machines

75 - Sys l
 -%
Calculating Clamp Tonnage Requirements

How are clamp tonnage requirements determined?

i- Anticipate the pressure distribution inside of the mold
I. Determine the projected area

C F = A~PROJECTED
~ ~ ~
2,000 Ibs per Ton

;r A = Area projected by plastic onto the parting line in square inches (in2)
;. PM = Average maximum mold pressure in runners and cavities during filling
(dynamic) and packing (static)
How is the Clamp Force Generated?
; Pressure is generated across the mold cavities as the mold is filled and packed
r The pressure across the parting line tries to force the mold halves apart

What if you do not know how much pressure is in the mold?

Why is setting the clamp force important? - SYS I
 B
Machine Problem 1 -
1. Inside Diameter of the Injection Cylinder 7.5 inches
2. lnside Diameter of the Barrel 2.25 inches
3. Inside Diameter of the Clamp 24 inches
4. Full System Pressure 1,800 psi,

Mold
5. Part is round 6 inch, and has two holes, one is .50 and the second is .75
6. Runner is .25 width and a total of 4 inches long
7. Material data sheet suggests 3 ton per square inch

Machine
8. What is the R,?
9. How much plastic pressure is this machine capable of?
10. Each linear inch of screw travel represents how many cubic inches?
11. How much clamping force (tons) is this machine capable of?
12. What is the maximum average pressure at the parting line without flashing?
13. With back pressure set at 100 psi,, how much plastic pressure is needed for screw
recovery?
14. How many tons does this mold require?
77 -SF l
15. Based on tonnage, how many cavities could this mold be?
 @
Machine Safety
Injection molding is a high temperature, high speed and high pressure process with a resulting high
potential for injury.
Devices are placed on injection molding machines to assure the safety of those who work on them.
These devices include:
Main disconnect
k Cuts off all power downstream of the switch
Emergency stop button
r Breaks electrical circuit to stop the motor
Safety gate (operator side)
i Opening activates three redundant safeties that prevent clamp and injection movement
Safety gate (non-operator side)
r Opening stops motor or pumps
Purge guard
i Opening prevents carriage and screw movement
Fixed guards
i Protect against pinch point and temperature exposure
Electrical panel guards
k Cannot be opened unless power is disconnected
L

A machine that has inadequate or non-operational

79 - SYS I
safety guards is a significant danger to personnel!
 i%
Suggested Safety Checks on Equipment

Check Desired Result

Depress E-Stop No Machine Movement
Open Front Safety Gate No Clamp or Injection Movement
Open Rear Safety Gate Motor 1 Pump Off
Open Purge Guard No Injection Movement
Open Electrical Panel Should Not Be Possible Unless Main
Disconnect is in the OFF Position

80-Sysl
Injection Molding Economics
> Is the profitability of your company
important to you?

'i. Are there opportunities for your company to

be more profitable?
 d
START
3 Elements Determine Cycle Time
t

For Profitable, Quality Molding,,,

FILL FAST

8,
4
COOL QUICKY
D E M O L D A S FAST
A S POSSIBLE
CONSISTENTLY
-
85 Sys I
 --%

MORE OPPORrUNlW 72)SELL 77ME 70CU5'IZ)MERS 88 - SYSI

 0
--.

Process Control In
Injection Molding

Goal:
> Reduce Normal Variation by
controlling critical parameters
P Helping Molders Succeed

89-S~SI
 The Molding Problem
Simply Stated 1

PRE55URE LOSSES ARE LARGE

PRE55URE L O S S E S hRy
The greater the PRESSURE LO55,
the MORE the mold acts a5 an
AMPLiFIER QF OTHER PKOCESS VARIATIONS.
-
91 Sys 1
 t
-".

This is caused by:

Inherent variability of raw material due to the nature of
the polymerization and additive compounding processes.

92 - Sys I
 9
-,

Large pressure losses that are inherent when plastic

flows (dynamic) and is pressurized (static)
3 ,

(1-

SHORT SHOT

.YO0
Nozzle

Pressure
Loss
Runner

Pressure
Loss
Cavity

93 - Sys l
 R
Dynamic Pressure Loss Worksheet
Purpose:
To determine the pressure that is lost from the injection unit throughout the part.
+ Equipment needed:
1 molding machine
1 mold
1 purge plate (this may be needed for recording an air shot)
+ Set up machine to run a standard Decoupled II process. Confirm that the part is 95-98% full
+ Retract the injection unit
Turn off pack and hold. Do a fill only into the air. Record peak injection pressure. Save the shot
Use the purge plate if the machine is not capable of injecting into the air without the injection unit
being forward
Return injection unit
Adjust shot size to fill the runner only. Record peak injection pressure. Save the shot
Adjust shot size to fill just inside of the gate(s). Record peak injection pressure. Save the shot
Create a fill only part. (95-98%full) Record peak injection pressure. Save the shot

Air psi,:
Sprue Runner:
Inside Gate:
Fill Only: 95 - sysI
 Z
--I 0
-4 3
z VISCOSITY + I2 2
(D
V) z
6
z 3
8
n a E
s 3
5 2.
zXJ 3 (D
CQ 3
2;
rn 0 1.
=2
z e
0
I)r

a
1 0
3
V)
.<I
-I 3
CD
;J
(D
07

V)
Y
-

'W
 Z
a-

Process control involves reduction of normal variation

of all primary variables during all phases of the cycle.
START
3 Drying the plastic
P Melting the plastic
t
3 Filling the mold
i;. Packing
3 Holding
9 Cooling rate and time
> Releasing the part

99 - Sys I
 s
-
Strategy

> Molding from the Plastics' Point of View

\i. In-mold is the focus
> Each cavity is a process
h Machine and location independence
> Molding by the numbers

100-sys I
 *
.,

Procedure:
Establish a target for each plastic variable
9 Determine a starting setpoint for control
> Measure result
3 Adjust controls
P Repeat until optimized
P Document

-
101 Sys l
 w
0
-+ 0O n (D 3
-0 -I-l Q 5
m
$B E5Te: s: g5 0 E
3a 2$
395' V) =.v e. 0 *
e z Pm
g z ps a3
- 2
2
0
3
-

3&La
8 2%
0 P
gg 2
8 rn
6% o
3 -. 9.

o
v z
I?.

I i '
d

W
V)
5
-

j l
 Decoupled #3,3-Stage DECOUPLED MOLDING'^ &
PROCESS SHEET

Mold # Material Cycle Time

Template Name

3W30 Back ppsi

Fill time Pan@)weight

Peak plastic pressurelmold air -

Pack rateltime Setpoint

Peak plastic psilgate
Peak plastic psilEOF
FkP part(@weight
Hold time Hold plastic psi
Gate seal Final pan weight

Cooling timer
Coolant:
Temp, FIOW

Force
103 - Sys l
Type
 -L
The Injection unit as a Melter
The barrel, end cap and nozzle are covered with electric heater bands
i. Those heater bands are grouped into sections called zones (ex. rear,center, front, end cap,
nozzle)
'I. A thermocouple is placed (preferably in the steel) to measure the temperature of each zone
';. The heater bands and thermocouple for each zone are wired to a controller where a
desired temperature can be set
k Heat from the bands is conducted through the barrel and into the plastic inside which
initiates the melting process
2. When the machine is cycling this conduction heat only contributes approximately 20% of
that necessary for melting and is primarily used for control

Where does the other 80% of the heat come from?

Seat

No

Check Ring -
108 Sys I
 Plastic Temperature
Target temperature for plastic? Screw rotation speed -Where to start?

Initial set-points for the controls that ii RPM:

affect plastic temperature:
Shot size - Where to start?
Temperature - Where to start?
\;. Cubic in. or cc:
Feed Throat:
ii Rear Barrel Zone: Decompression -Where to start?
% Center Barrel Zone:
Distance or volume
> Front Barrel Zone:
How do these controls affect plastic temperature?
> Nozzle:
P How is plastic temperature measured?
Back Pressure -Where to start?
"i Which controls should be adjusted for
Plastic Pressure: optimization?

i; How to document independent of machine

setting?

-
109 Sys l
 Melt Model: Standard Screw
The feed section initiates solids conveying

--
I.There is also some compaction and heating of the
resin.
At the beginning of the transition, the resin is
further heated and more compression occurs.
2. The solid resin is forced against the barrel causing
a sliding friction. This frictional heat creates a film
of melted polymer on the inner barrel surface.
 -2-
Most of the melting takes place in the transition zone
BARREL

COLD MATERIAL TRANSITION AREA MELlED PLASTIC

-- \
screw-ro7
(melted and unmelted plastic)

'-- -- -- -
V
The polymer is divided into three parts:

L a compacted solids bed

> a melt film along the barrel surface
i. a melt pool
The melt film is collected by the advancing flight. Melting continues
to be the result of sliding friction of the solids bed against the heated
barrel.
This is rapid efficient melting something like melting an ice cube
by pushing it against a hot grinding wheel 111 -syst
 I

BARREL

COLD MATERlAL TRANSITION AREA MELlED PLASllC

-- \
scterrobt
(melted and unmelted plaste)

'-- -- -- --
V
Melting continues and the size of the solid bed decreases, while
the size of the melt pool increases.
> As the channel gets shallower, shear rate increases
> The melted polymer continues to heat
P This may be undesirable

112-Sysl
'i. The solids bed breaks up
> The un-melted pellets are distributed throughout the channel like ice cubes in

;The efficient melting by friction of the solids bed against the barrel stops
3 -
Only less efficient melting remains like heating water to melt ice cubes
3 Heating of the melt continues in the shallow metering sections
It is possible that there remains un-melted pellets resulting in non-uniform melt
> Greater mixing can be achieved by reducing the channel depth
i. Increasing back pressure moves flow from an open discharge condition
towards a blocked discharge condition
> This can cause overheating and less output per revolution
9 Long fibrous fillers can be broken with higher shear rates
 L
-"

SCREW RPM: Should be as slow as possible without

increasing cycle time.
H Reduces maximum and overall shear rate
; Shears material more uniformly

; Reduces fiber breakage in filled material

; Provides more melt homogeneity
z Think circumferential speed when moving to another machine

Screw RPM determines the maximum shear rate of the plastic ,,,- , ,
 I
--
Back Pressure
HYDRAULIC PRESSURE

INJECTlON S P M

PLASTIC PRESSURE
IN THE BARREL
~ P S C
-
BACK PRESSURE
m a
=@Sam
-
B Injection cylinder works as a pump pushing oil back to tank
+ Changes the amount of heat added by shear
:i Changes temperature of the melt quickly (temporary)
> The change will not be totally sustained unless zone temperatures are
also changed
Changes the amount of shear mixing or homogenization
2 May increase fiber breakage in fiber-filled materials

115-Sysl
 "' &
--

L %>.
4
HEAT
r -.DON'Tb
& A

HEAT

P Feed throat temperature effects melting and moisture splay

P Must be cold enough to prevent clumping and hot enough

for dew not to form (1 05" F or 35" C minimum)

116-Sysl
 @
-.
Make plastic stick to the barrel
early in the feed zone

r Tacking Temp.

> Find the Tacking Temperature

40

Coefficients of friction for polystyrene (at 70" F) sliding

5 on steel surfaces (at temps ranging from 70-550" F).
-
x=
.g
o
30 Polystyrene was Dow Chemical Co.'s Styrene 666U.
Rapid reduction of friction between polystyrene at
C
room temperature (70" F) and hot steel (over 375" F)
$
.-
0
.- can cause slippage on the barrel near the
5 20 throat in the rear zone area.
8
10 i. Find the rear zone temperature
75
which results in the shortest
50
25 screw recovery time
0
0 100" 200° 300' 400' 500' 6w°F
-18' 38 93' 149' 204' 260' 316OC
117-Sysl
Steel temperature
 -I
-

BARREL TEMPERATURE P R O F I L E
1. Set all zones at the desired melt temperature
2. Run the machine on cycle
3. Take the melt temperature
4. Adjust the center and rear zones to achieve desired melt temperature
5. This may not be possible on machines with an incorrect screw for the
material being molded

If screw recovery problems exist, do step 6

6. Set the rear zone to make the plastic stick to the barrel and to obtain
faster screw recovery (temperature at which minimum screw recovery
IIE-S~SI
time is achieved with a constant RPM)
 Taking Melt Temperature

+ Monitoring is hard to do on a continuous basis

Plastic is an insulator
Nozzle and thermocouples are conductors
= Measure nozzle temperature
Infrared techniques are expensive and there are problems
J Looks through some plastics
J Not robust
9 Use 30-30 approach
Heat probe to 30°F over maximum barrel setting
Purge on cycle
= Immerse for 30 seconds and read
k Changes in melt temperature can be detected using advanced techniques to
measure effective viscosity during the shot
 -B
Taking Melt Temperature, cont.

'i. lnfrared thermometers can be used to measure melt temperature

The unit must be operating on the proper wavelength to sense

temperature of the plastic

J Plastics emit infrared at different wavelengths - some infrared units

will not detect plastic temperature accurately so care must be
taken

With the correct hand-held unit, purge on cycle, use a standard

catching device and read at a fixed time after the purge has been made

ij Generally, infrared sensors that go directly into the nozzle are not a reliable
way of measuring melt temperature

lnfrared spectrum is wrong due to the need to translate through fiber

optics
Quartz windows do not withstand the rigors of production molding
120-SysI
 t
- .
Melting the Plastic
Plastic melt temperature is a primary process variable
and must be monitored.

Barrel temperatures, back pressure, and screw RPMs are settings

which influence plastic temperature, therefore controlling them is
important.
Plastic temperature does not correlate directly to barrel temperature.
'f- Especially from machine to machine
Different screws
Different residual back pressure
Different temperature controller dynamics
121 - sys l
 Mixers B-

Mixing Screw
Barrel

Flow Direction

i. Breaks up tornado-like flow of melted plastic in the screw flights

'i- Is placed in the metering zone to mix melted plastic
'i. Must not cause high localized shear
r Provides more uniform melt temperature
i. Provides more uniform color dispersion
i. Faster purging 1 quicker color change
-
122 SYS I
 B
"-"
Lab Experiment #I
Melt temperature measurement

Equipment:
';.
Molding machine
= Material to test
Hand-held pyrometer
Gloves and hood
Container to catch material
Pre-heater for thermocouple
Watch with sweep second hand or stop watch
r Procedure:
Purge the machine on cycle and catch a purged shot into the container and
take temperature by conventional means using cold thermocouple
If time permits have several people record temperatures using this approach
Calculate the average and range of readings
On successive purge cycles take temperatures as follows:
d Preheat probe using heating device to degrees (or 30°F
over highest barrel setting)
4 Purge shot into container

d Insert preheated probe into melt center

d Take reading 30 seconds after insertion

Have several people repeat procedure in Step 4 and record results

Calculate the average and range of readings
Compare with readings in Step 3 and draw conclusions 123- sys I
 -t-
During filling two things must be available:
> Pressure in abundance (Ri)
>. Flow sufficient to achieve the desired flow rate (pumps or
accumulators)
During RII, the set pressure Is a secondary variable cn
LOAD
pa.

Plastic Flow Rate is Keyl

On electric machines available plastic pressure and

injection rate are analogous to Ri and flow rate 126- SYS I
 Key Points

When purchasing a new machine:

i;. Specify pressure first - high intensification ratio
';. Obtain enough flow capacity using pumps and
accumulators to create necessary flow rates
> Both pressure and flow must be available to obtain fast
flow rates

Plastic Pressure in Abundance Starts with

the Intensification Ratio of the Machine
-
127 Sys l
The ability to control injection rate during fill and pack is
the most important measure of a machines capability...

Plastic Flow Rate is Key!

Open or Closed Loop?

(Why do you care?)
 Injection Molding Approaches
Traditional Molding:
> The original method of molding
';. Fill and pack on first stage
> Use only enough first stage pressure to pack the mold

DECOUPLED MOLDINGSM:
';. Use abundant first stage pressure
Separate the filling or velocity phase of molding from the packing
or pressurization phase
 @
-.

DECOUPLED MOLDINGSM
Definition:
A process control method that addresses how the machine controls are
used to fill and pack plastic into the mold.

Objectives:
> Injection speed reacts only to the machine's velocity setting(s)
i Constant and repeatable injection speed shot to shot, year to year,
regardless of any effective viscosity changes
i.. Reduce part variation due to effective viscosity variations
r. Gain the ability to fill fast to minimize effective viscosity variations
7 Make the process capable of always making good parts
'i- Make polymer rheology work for you

130-Sysl
 *

THE INJECTION UNIT

SCREW INJECTION RATE Plastic Flow Rate

Plastic flow rate IS directly related to screw injection rate
unless the check ring leaks [some leakage must be assumed)

or 1 SECOND OF
CU INISECOND 131 - SYSl
MOVEMENT
PLASTIC MOLECULES
READY TO FLOW

3 FREE TO MOVE
P NO ORIENTATION
P LIKE WORMS IN A BUCKET
.b LEAST ENERGV TANGLED STATE 133-sys I
 2

UNORIENTED PLUG
ORIENTED AND FLOWING

ORIENTED LAYER
FROZEN SKIN

SECTION A-A

INCREASED

UNORIENTED PLUG

ORIENTED AND FLOWING

ORIENTED LAYER-
FROZEN SKIN
SECTION A-A

GRADIENT

134 - SYSI
 --D
One of the hardest concepts in Plastics: As speed
increases, the material gets thinner and easier to push

Non-Newtonian Behavior of Polymers

THICK

t 7

.-
High sensitivity to
machine fill speed
fluctuation

Crossover point

g
z
0
v,
Low sensitivity to
machine fill speed
fluctuation

THIN

SLOW FLOW RATE FAST 13s-sysl

 u i--- B
For the data in the box: High 1 -',,?s;:/fl
\'iscosity
1. Calculate an effective (Stirr)

I';! ;
- .............................................
viscosity for each shot
2. Scale the y axis for the - .........:.......................................
viscosity calculations from
low to high - ..............................................

3. Calculate a shear rate for

- ..............................................
each shot (lh) I :

i :

4. Scale the x axis for the ,.............i ................. . . ;

- ........ .....
shear rate from slow to i :

fast ............................................
., .
, ,
1 :
5. Plot the data by finding an I
- ........;.I ..i\ ....
, .......
;., .;. . . . ..;......
interconnecting point on :. ,, :.
... . > .
the graph for each shear 3 % :

rate viscosity calculation

. . , ..
- .........:.. ';
...... .........;..........:..........1 .........j+ ....... -'/.A;
;..;"5..;. ....A.Fip
7'
.., \ :.
.. , . ..
6. Connect the dots by _ .....................
.
.
,. .................
,
.. .
j .._
.. ............................... :.......................
drawing a line through . . .
them - ....................;.........!
j _.!' 7 ........

...:..........; .__._.~.:_ : _
....................:..
:-.

Low
Viscosity 0 I I I 1 1 I I I I I
(Easy) 1332 5
Slow Fast
Shear Rate or Flow Rate
1 / (t) Fill Time

What does this curve tell us?

136-Sysl
 -3
Plastic Flow can change viscosity 100 times
more than temperature, therefore:

2. Flow must be controlled

i Flow varies with check-ring consistency
i Variation in plastic flow cannot be detected in machine variables
2. Flow must be the same in all cavities to have balance
> Flow makes marginal venting problematic

UNDERSTANDING THIS IS
HELPING MOLDERS SUCCEED 137-sysl
 E
-
If a mold can be filled to 95 to 99% full with one speed without
flash, burns or other adverse effects, then linear injection can and
should be used.
4 This is the fastest way to fill
P This is the simplest set up (KIS)

If the mold cannot be filled to 95 to 99% full with one speed of fill,
then programmed injection must be used or the mold must be
modified.
> Constant velocity
3 Programmed injection

If cavities are blocked, screw velocity must be

changed to achieve the same, mold cavity fill time.

3 Less volume of mold to fill

"v Need the same cavity fill time
to achieve the same part

138 - SYSl
At the instant just before the cavity is full, the hydraulic pressure built up in this injection cylinder
represents the plastic's instantaneous resistance to flow. This pressure and the fill time can be
used to measure the dynamic resistance to flow.

Transferring just prior to filling the cavity is the essence INJECTION

of DECOUPLED MOLDINGSM.

DYNAMIC PRESSURE
LOSSES
PRESSURE AT GATE

PRESSURE AT END
OF CAVITY

It i s necessary to have abundant pressure available to achieve the injection rates set on the
flow control device.

The cylinder pressure must never reach the set pump pressure during fill.

The hydraulic pressure reached during fill will vary:

. If fill time is constant, the peak pressure developed varies directly as the viscosity of plastic
;
varies
;
i This hydraulic pressure variation can be used to monitor plastic viscosity variations if fill
time is well controlled
139-Sysl
 -D
Plastic Flow
Set a target flow rate of the plastic:
Initial set-points for the controls that affect plastic flow rate:
First stage injection pressure - where to start? psi,
First stage injection speed - where to start? In3/sec
First stage injection time -where to start? Seconds
Transfer from fill position -where to start? ln3

How do these controls affect plastic flow rate?

How is plastic flow rate measured?
Which controls should be adjusted for optimization?
How to document independent of machine settings?
Before injection occurs, what has to be done?

140-Sysl
 -C
PRESSURIZING THE
PLASTIC

In normal (Hydrostatic) fluids such as

oil, static pressures equalize through-
out the system (Pascal's Law).
142-Sysl
IN PLASTICS this is NEVER TRUE
 F
PACKING
...separate from fill

PACKING BUILDS UP STATIC PRESSURE

WHILE PUTTING ALL OF THE PLASTIC
INTO THE CAVITY.

PACKING PROVIDES THE PRESSURE

TO IMPRINT THE CAVITY SURFACE
ONTO THE PART.
3,000 psi at end of fill should be considered minimum 143 - Sys l
pack pressure for most applications
Plastic Pressure Gradient
(Static Not Dynamic)

Pack and Hold

3 Packing Pressure Over Time

P Packing Velocity to a Cavity Pressure
> Holding Pressure & Time
 STATIC PRESSURE
GRADIENT
Variations caused by VARYING MATERIAL VISCOSITIES
using constant machine conditions (filled and packed)

STATIC PRESSURE LOSS

CAN BE MEASURED ONLY WlTH MOLD PRESSURE
SENSORS
VARIES INDIRECTLY WlTH EFFECTIVE VISCOSITY
PRESSURE LOSS IS ALWAYS LARGE IN PLASTICS
146-Sysl
THE MAJOR CAUSE OF PAKT VARIATION
 Example of Decoupled I1 Molding
(2-Stage Control)

Better
But Not
The Best
What effect will a +/- 10% viscosity change have inside the mold?
Can parts be contained if a viscosity change happens which
requires re-centering the process?
How? -
47 sys I

This slide is available in color at the back of the book.

 The mold~rig
problem, slrnply stated @
-
THE EFFECT OE..
Vl5COSlTf VARIATIONS @ P R E ~ ~ ~ ~ f

46% END OF FILL PRESSURE VARIATION

PLASTIC VARIATION IS
WORSE WITH THIN WALLSI 148 - Sys I
@ 1
-
2
V)
m
2
C
.-0
C,
.-a
z
>
.-h
C,
V)
8
V)
5
Q)
.->
C,
0
Q)
l=
W
8
X
V)
V)
0
t!?
3
V)
V)
t!?
a
II
8
C
.-
+
0
.-a
z
>
8
W
 D
- ,

Plastic is compressible 112 to 314

percent per 1,000 psi,.
This means overall dimensions will change on average 1/2 to 3/4 percent per
1,000 psi of plastic variation.
Other factors:
ii Direction of flow vs. transverse to flow direction
i j Long fillers such as glass

i Crystallinity

REMEMBER:
A short shot is zero pressure in the cavity
at the end-of-cavity. 150 - SYS I
 Q
- .

HOLDING PLASTIC
In

After t h e mold le packed, PLASTIC must be

RETAINED or held In the mold untll It le
PARTIALLY 50LIDIFIED.

b The amount of HOLDING PRESSURE afid I t s

duration (HOLDING TIME) determine the
AMOUNT OF PLASTIC RETAINED IN THE CAVITIES.

CLASSICALLY, ALL MATERIAL PACKED INTO THE MOLD

15 HELD IN UNnL THE GATE SEALS.

THERE ARE MANY EXCEPTIONS 70 7HIS RULE 152-sy~I

 Plastic Cooling *'

Effective cooling means that the heat that was

added to the plastic to initiate flow, must be
removed as quickly as possible.

This heat removal process involves two trips:

i;. Heat out of the plastic - slow

'i. Heat out of the mold - faster

-
155 sys I
 P
-
Plastic Cooling

PLASTIC
RATE
AND
TEMPERATURE
MOLD SURFACE
TEMPERATURE
The Rate of Heat Removal.

The Time to Remove enough Heat to Keep the Part Stable.

-
156 SYSl
 23
--

To Improve the Cooling Rate:

i;; Change the plastic
2 Change the type or content of additive
> Reduce wall thickness
> Clean mold surface
3 Keep the plastic against the cavity surface longer
3 Increase the plastic temperature
While creating a higher difference, would also result in more
heat to remove
+ Lower the mold temperature
The lower limit for mold temperature is often dictated by product
considerations
4 Crystallinity
4 Surface Characteristics
4 Gloss
4 Cosmetics
4 Stress
Warp
157 - SF l
 -B
When a mold is filled with plastic, the heat content of the material is
transferred into the mold.

fd
I . '

LOST THROUGH
THE PART = 40%
MOUNT of HEAT

> A portion of that heat exits the mold while still in the parts
2 How quickly the remaining heat is transferred into the mold is determined by:
The difference in temperature between the plastic and the mold

"The best cooling system in the world

won't take heat away any faster than the
molded part will give it up."
158-SySl
The ability of a plastic to change temperature
 -$2

The heat transferred into the mold exits three ways:

;Conduction through the platens
i Free convection into the air
i- Forced convection into the coolant
channels
Usually the largest of the three and is
used as a control factor of the
process

Coolant efficiency is a function of:

Y Coolant line location, size, and spacing
> Temperature of coolant T2

Lowering is only effective to a point

FLOW RATE -
b
(50°F)
> Flow rate of coolant
% How the cooling channels are connected

159-Sysl
 -E"
How should cooling channels be connected?
IN

Series Parallel

IN OUT f
OUT
'i. Uses least coolant > Provides maximum cooling if
3 Has largest pressure loss coolant is available
9 Largest temperature differential ij Uses the most coolant
k All channels get the same L Lowest pressure loss
coolant flow + May waste resources
i j Flow channels with highest
restrictions get least cooling

160-S~SI
 --
Plastic Cooling
General piping rule:

i Use the fewest flow circuits that will provide turbulent flow
in all channels with a maximum coolant AT between the
inlet and the outlet of 4°F (2°F on critical jobs)

Control the flow in all parallel flow channels

7 Without turbulent flow in the channels, the outer layers of

coolant near the walls insulate the center of flow and
efficiently reduce the volume of fluid available to carry the
heat away

162-Sysl

Flow Flow
 8
The tables below show the flow necessary in commonly
used mold cooling lines to obtain turbulent flow:

GPM NEEDED FOR TURBULENT FLOW:

Note: Twice the flow rate is needed for
50150 ethylene glycol mix for turbulent flow.

164 - Sys l
 d
HOW HEAT IS
TRANSFERRED

Must have turbulent flow to maintain

low Tc and optimum cooling.
Qi=hi(Tp-Tmsi)
Q2=h2(Tms2-Tc)

THERMAL EQUlLiBRlUM
Ql=Q
May take a long time .... 165 - SYSl
Is disturbed by cycle variations
 @

Plastic Cooling Rate and Time

Target moldlpart surface temperature?

Initial set point for the controls that effect part temperature.

Coolant temperature - where to start? Degrees (F or C)

Coolant flow rate - where to start? GPM or LPM

Cooling time - where to start? Seconds

How do these controls effect part temperature?

What determines when a part is cool enough?

Which controls should be adjusted for optimization?

How to document independent of machine settings?

-
166 SYSl
 Decoupled #2,2-Stage D E C O U P L E D M O L D ~ N G ~ ~ -$4
PROCESS SHEET

Mold # 1234 Material ABS Cycle T~me31.0 sec

Template Name NIA

30130 446" F Back ppsl 1000

2
v a*
*A WB-WWY-' *4
F ~ tlme
ll .79 sec. Part(s) we~ght 4.33 g.
Peak plastlc pressurelmold 12,479 pps~ alr =psi

Pack tlme c PSI 11,000 vpsi

FBP part(s) we~ghl 4 67 g.
Hold tlme 9.0 sec. Hold plast~cPSI 11,000 ppsi
Gate seal Yes Flnal part we~ght 4.76 g.

Coollng tlmer 16.0 sec.

Coolant:
Temp,, 102.7" F Temp, 105.4' F Flow 1.5 gpm

Force 45 Ton
-
167 SYSl

Type Hyd.
 --I
Sensor Placement
INJECTION
PLASTIC PRESSURE CYLINDER PRESSURE
AND TEMPRATURE
I N THE BARREL
INJECTION SPEED

PRESSURE AT GATE
UNIT

PRESSURE AT END
OF C A V I M
Injection Cylinder End of Fill in a Cavity
k Hydraulic load ;i Non-fill
ii Response 3 SPC
'i. Repeatability > Automatic Part Containment
3 Viscosity Measurement
Screw Position Gate End of Cavity
> Shot size 3 Pressure drop across cavity
% Decompression 3 Degree of packing
2 Cushion position ii Hold time optimization
> Repeatability > Control point
& Actual speeds vs. set points 170-SYSI
 a
-

A. Summary Screen: Displays summary data values in a

running bar chart for analyzing trends over time.
B. Cycle Graph Screen: Displays each cycle versus time as a
graphical waveform. 171 - Sys l

This slide is available in color at the back of the book.

 a?-

Injection Pressure

0
-
Fill Time
4
Pack and Hold Time
4
Screw Run Time
F

15
TIME (SECONDS)
173-Sysl

This slide is available in color at the back of the book.

 STROKE (CuIn)

2
0)

m
B
al
B V)
D)
C 0
pl.
B
e
(D
-.
3
zs
0
2
2
2
- 0
3
0) V)
I.
0-
rC
W
X
0, 5.
5
al
3
0-
0
0
x

4-P

V)
%
-

!B
 - .

Strategy B
Blueprint Of The Process
;- No cavity pressure information required
9 Not all primary variables

0
0

s t
':A
II
Injection

h
&

zg
1 1
I I - - Stroke
'-\J
c C - -

-3 / I ) - - - -

I I,'
zg f 1 \\
ZE
m o 1
/
/'
/)-------- -1
I
\
\
\
WPC I / I \
I / I \
\
I /'
1,
I
1
C-
,-- - - - - -
4
\
\
TI
0 TIME (SECONDS) 15
175-Sysl

This slide is available in color at the back of the book.

 @
-~
Strategy A
(with Cavity Pressure)
> Effective Viscosity
Important Machine Variables
k Primary Variables
Plastic Temperature
Cavity Pressure Gradient
Cavity Fill Times
Cooling Rate and Time
J Cavity Pressure Slope

J Mold Cooling System

Any Secondary Variables Appropriate For a Special

Application

-
176 Sys l
 -@-
End of Cavity Pressure

20,000
> Most Variable
9 Best For Monitoring
ji Contain Short Shots!!
h
P
5;
P
V

2a
VI
ta
P
J Peak

0 T I M E (SECONDS) 15
-
177 Sys l

This slide is available in color at the back of the book.

 82
-"

Gate End Pressure

F Best For Control

ii Fill Dynamics
> Gate Seal

Sudden Pressure

4
0 Cavity Fill
Time TIME (SECONDS)
178-Sysl

This slide is available in color at the back of the book.

 1

Strategy A
Blueprint of the Process
20,000

n
P
5;
P
u

23
V)
V)

2P
' ,
0
4'-'-*

# -
- - -....-
\
\
\
Gate End
Cavity Pressure

- --.
--/-.- -
\
1 0
I /
I I
H
' '\* I
Endof/
Cavity
\

I I Pressure
\
\
--. -.
I \ , -.
0 TIME (SECONDS) 15
179 - Sys I

This slide is available in color at the back of the book.

 hl
0
w
PRESSURE (PSI,) 8
0

E
P,
0
3
I.

3
CD
b
3
P.
m
3
E
0
e
0
P,
P

T-

I "@
 -I
Create Information From This Data
1. Is this process pressure limited? /

2. Is this process Traditional or Decoupled?

3. Is it a full part?

4. Is the gate sealed?

5. What is fill pressure in plastic?

6. What is pack and hold pressure in plastic pressure?

7. What is the peak pressure at the gate?

8. What is the peak pressure at the end of the cavity?

9. What is the back pressure in plastic pressure?

10. What is the machine fill time?

11. What is the in-cavity fill time?

12. What is the screw run time? 182-SYSI

 --L
If you don't know these by now,

pnES~lj~E
IN THE MOLD

COOLING 184- SYSl

RATE & TIME
 Process Monitoring
Decisions ?!? Decisions?!?
 2
.-a

Monitoring & Containment Strategy

Makes "Just Monitoring" an integral component of
quality to the customer

ww
89%

Initially can set bands narrow for accept and wide for shorts and flashed,
then tune alarms to minimize parts to be sorted
This minimizes direct labor for inspection and assures quality to the customer
186-Sys I
Process Capability Strategies

0 Use Unifor

Drive the Strategy With

Information Based on Data
187-S~SI
Helping Molders Succeed
 -P-
Decoupled 111: Three stage molding

;
. Objective: fill the mold fast, profile by screw position. When the cavities
are 85-95% full, transfer to a slow, controlled velocity pack stage.
Packing is complete when the cavity pressure or screw position transfer
completes packing the part(s)

_I___--".- _

-
189 Sys l

This slide IS avarlable in color at the back of the book.

 I

Decoupled 111 Molding

INJECTION
PRESSURE CONTROLLED GATE END
CAVlM PRESSURE

END OF CAVlM
CAVITY PRESSURE

MACHINE PROVIDES THE PRESSURE IT NEEDS TO FILL

AT A CONSTANT SPEED AND PACK TO A PEAK CAVITY
PRESSURE ALSO AT A CONSTANT SPEED.

THIS IS THE MOST CONSISTENT METHOD OF

MOLDING CRITICAL PARTS!!
190-Sysl
 C.
*-

Example of Decoupled I11 Molding

--._^I__ ,___----'

The
BEST!

What effect will a +I- 10% viscosity change have on the

end of cavity pressure of this mold? How much better is
this than Decoupled II in the previous example?
-
192 Sys I

This slide is ava~lablein color at the back of the book.

While there are distinct benefits to choosing one
technique over another, it is very important to
consider that each approach requires specific
machine capabilities to be successful. The
minimum capabilities for DECOUPLED MOLDINGSM
are:

P The machine is not pressure limited by the set injection pressure or

the mold being filled
i;. Robust injection speed control
9 Position transfer
9 For Decoupled I& 111, cavity pressure transfer
i;. Excellent low velocity control for Decoupled 111 (0-10% range)

193 - Sys l
 B

Ten key molding techniques for optimum process control

1. Use plastic temperature well within material manufacturer's

recommended range.
2. as fast as possible - consistent with quality
May be slow to minimize orientation
Decouple filling from packing
= Record fill time
Use techniques that keep fill time constant
3. Cut off or end filling by:
Position
4. End packing by:
Cavity pressure
Time
5. Hold plastic in the mold
PACK & HOLD
Know when the gate seals
Know if molding is being done with sealed gate or discharge

195 - Sys I
 @
."-"~.
Ten key molding techniques for optimum process control, con't.

6. Control coolinq rate and time

COOLING
RATE & TIME
Know rate of coolant in all flow channels
Know if turbulent flow exists
Know temperature in andtemperature out on cooling systems
Maintain a constant cycle
7. Don't use adaptive control techniques
Automated tampering
Amplifies random variations (common cause)
Only corrects for things which need to be fixed
8. Run screw as slow as possible - without extending cycle time
9. Don't use programmed back pressure

10. Don't adjust temperatures to compensate for material variations. Instead, adjust fill
rate (fill time)
Faster corrections
Only changes specific variables
Easy to quantify
196-sys I
 Decoupled II Molding

P Objective: fill the mold fast, transfer by screw position when

the cavities are 95-98% full. The ram inertia is used up just
before the cavities fill out, and 2nd stage hold pressure is used
to complete the filling and pack out the parts
 Example of Decoupled I1 Molding
(2-Stage Control)

Better
But Not
The Best
What effect will a +I- 10% viscosity change have inside the mold?
Can parts be contained if a viscosity change happens which
requires re-centering the process?
1 How? I
 Part of process control involves knowing if and when gate
seal occurs on all cavities for all molds.
GATE SEAL TEST - MOLD 418
Press 10, MR 1

;
; 4%

Without Instrumentation 3 :
I "i
C
we use part weight study 4.96

With illstrumentation we use post

gate psi curve including hold time

te Seal = Best Dimensional Control

owing discharge or backflow out of the gate after a set period of time:
P Can reduce compressive stresses near the gate
P Can affect pressure gradient caused warpage
 Data Analysis

A. Summary Screen: Displays summary data values in a

running bar chart for analyzing trends over time.
B. Cycle Graph Screen: Displays each cycle versus time as a
graphical waveform.
ST una Maras a U ! l PloH Pue W e d a u ! l ll!d 0
4 b 4 b -
T
arnssard y3ea
A w
n
rn
V)
V)
~~aed
arnssard p l o '8 C
n
rn
n
w
V)
H
w
u
/
yl
arnssard l l ! ~ 000'02
PRESSURE (PSI,) 20,000
STROKE (CuIn) 6
ISd Yead '
01 anp uo!gmpaa
arnssard uappng
 Strategy A
Blueprint of the Process

/
0
--- \
\ Gate End
\
I 0 (I\
\ \ \ Cavity Pressure
1 r \ \
\
/
1 I \
\
1 I End of \ \ \
\
/ " I Cavity \ \ \ \

/ I \ \
b I
Pressure \
\
\
\

0 TIME (SECONDS) 15
 Machine And In Mold Data

Strategy A

0 TIME (SECONDS) 15
I I I I I I I 1 I I I I I I I
I ooo'oz
 Decoupled 111: Three stage molding

Objective: fill the mold fast, profile by screw position. When the cavitie:
are 8595% full, transfer to a slow, controlled velocity pack stage.
Packing is complete when the cavity pressure or screw position transfe
completes packing the part(s)
 Example of Decoupled I11 Molding

I I I I
-
I he
BEST!

What effect will a +I- 10% viscosity change have on the

end of cavity pressure of this mold? How much better is
this than Decoupled II in the previous example?
> Gate seal
3 Check ring
k Clamp force calculation
2 Stability study with viscosity change (eDARFM)
> Shear rate curve
> Part weight study (on shear rate curve)
3 Shot size (20-80%) - Cushion evaluation
> Cavity balance
> Mold deflection
P Least pressure curve (on shear rate curve)
> Note any runner design problemlimprovements
P Pressure response? eDARFMneeded
> Moisture test on material?
3 Note 5s concerns issues
P Temp map of moldlcoolant line AT
> Note any tooling issues
> Temp map of part
> Linearity of speed. (instructor assist)
> Load sensitivity
P Water flow (if tool are there) - GPMITurbulent Flow
P Dynamic pressure loss study
P Setup sheet for Decoupled II Process
P Observe clamp motionloptimize

Tools Needed
Pyrometer Water Flow Gage Purge Plate
Dial indicator Calculator Scales
Moisture Analyzer Measuring Device to measure cavities
~---:LI- A:-:&-I
Melt temperature measurement

+ Equipment:
b Molding machine
F Material to test
b Hand-held pyrometer
b Gloves and hood
b Container to catch material
b Preheater for thermocouple
Watch with sweep second hand or stop watch
+ Procedure:
b Purge the machine on cycle and catch a purged shot into the container and take
temperature by conventional means using cold thermocouple
b If time permits have several people record temperatures using this approach
Calculate the average and range of readings
b On successive purge cycles take temperatures as follows:
* Preheat probe using heating device to degrees (or 30°F over
highest barrel setting).
* Purge shot into container
* Insert preheated probe into melt center
* Take reading 30 seconds after insertion
b Have several people repeat procedure in Step 4 and record results
b Calculate the average and range of readings
b Compare with readings in Step 3 and draw conclusions
 sneer on-~ewtonlan uenavlor or rolymers
Machine Type:

I 1 (t) Fill Time

ft = fill time; eff. Vis. = fill time X plastic psi; plastic psi = Ri X Hyd. psi
Non-Newtonian behavior into the mold

+ Equipment:
b Molding machine equipped with flow control valve to control injection speed
b Material to test
b Nozzle with proper orifice size
b Fill time clock
b Peak reading hydraulic digital gage or DART system to monitor hydraulic injection
cylinder pressure
b Graph paper
b Melt pyrometer and preheater
b Mold to test fill characteristics

+ Procedure:
b With the machine set for maximum 1st stage pressure and no hold, adjust injection
speed using the flow control valve or setting to a suitable speed for filling the mold.
b Adjust the 1st stage cut off limit switch to cut off fill so that the mold will not fill
(short shot). Be sure that the mold in question can be short shot without damaae,
Start cycling the mold with normal mold temperature control turned on
With mold warmed up adjust the 1st stage cut off position to insure a short shot as
injection speed is increased.
b On successive cycles slowly increase the injection speed while observing the short
shots. As the injection speed increases adjust the 1st stage cut off position to
maintain a short shot.
When maximum speed is reached (maximum injection speed setting or mold limiting
speed) adjust the 1st stage cut off point carefullv to obtain a short shot at least 90%
full.
b Set the 1st stage injection timer and injection total timer to at least 10 seconds.
b Record fill time and peak hydraulic pressure on data sheet.
On successive shots decrease injection speed and record peak hydraulic pressure
and fill time until the injection speed is too slow to fill mold.
b Record melt and mold temperatures.
Calculate the relative viscosity numbers and shear rate (lffill time) and fill out the
data sheet.
Plot the relative viscosity versus shear rate (lffilltime) to show non-Newtonian fill
characteristics of the mold.
Where do the rules change?
b What fill time should be used for this mold?
Machine #: # of Cavities:
Mold #:
Mat. Type: Date:

Purpose o f Test:
To determine the amount of imbalance in a multi cavity mold.

Equipment needed:
One Molding Machine One Weigh Scale
One Multi Cavity Mold

Procedure:
1. Set up machine to run a standard Decoupled process
2. Turn off pack and hold pressure and time
3. Make a fill only shot and record the weight of each part - (No Full Parts)
4. Calculate the imbalance for SLOW, MEDIUM and FAST injection speed
(Be sure the record the lnjection Speed and Cycle Time)

FAST INJ. SPEED: inls MED. INJ. SPEED: inls SLOW INJ. SPEED: inls

CYCLE TIME: s CYCLE TIME: s CYCLE TIME: s

Cavity # Part Weight Cavity # Part Weight

1 1
, I
2
3
4
5
6
7
8

Fast Imbalance: YO 1- Medium Imbalance: 1- Slow Imbalance:

Heavy Part - Light Part

X 100 = % Imbalance
Heavy Part

5. Draw Conclusions:
Acceptable amount of imbalance < 6%
Choose the fastest Injection Speed with an imbalance 5 6%:
If > 6%, tool should be sent out to be balanced. Review with Supervisor.

Recommendations:
Machine # # of Cavities
Mold # Cycle Time
Material Type Date

Purpose of test:
+ To determine how much control
there is over injection speed.
Equipment needed:
+ One Molding Machine i
Procedure:
+ Set up machine to run a standard
Decoupled I1 process.
+ Turn off pack and hold pressure and time.
+ Adjust the transfer position to make the fill only shot 80% full. This will ensure a
short shot when the injection speed is increased.
+ Raise the injection timer to the machine maximum
+ Set the injection speed at the lowest setting.
+ Take a shot and record the fill time.
+ Double the injection speed setting and take another shot. Record the fill time.
+ Double the speed setting again.
+ Keep doubling the injection speed until the machine is at its highest setting.

INJECTION EXPECTED ACTUAL PERCENT

SPEED FILL TIME FILL TIME DIFFERENCE

Average percent difference:

Actual range of linearity:

Draw Conclusions:
-
([I
3
4
2
-
([I
2 E
2 -
I
i=
i
i
E
I=
m
- $
0
ii a,
a
-0 x
a,
4
W
0
a,
a
X
W
Machine # # of Cavities
Mold # Cycle Time
Material Type Date

Purpose of test:
4 To determine how repeatable the check ring is.

Equipment needed:
4 One Molding Machine and Mold
4 One Weigh Scale
4 Calculator

Procedure:
4 Set up machine to run a standard DECOUPLED I1 process.
4 Turn off pack and hold time and pressure. Increase cooling time to compensate
for change in cycle time.
4 Make 10 fill only shots, weigh the parts, and runner if applicable and record the
weight.

SHOT# SHOT WEIGHT

Average

+ Calculate percent of change:

Heaviest Shot - Lightest Shot

X 100
Average Shot Wt.

Actual test results:

Machine # # of Cavities
Mold # Cycle Time
Material Type D P

Purpose of Test:
+ To determine to what degree the molding machine is sensitive to a change in load.

Equipment Needed:
+ One Molding Machine
+ One Data Acquisition Device
+ One Purge Plate

Procedure:
+ Install the Data Acquisition Device.
+ Set up the machine to run a standard Decoupled I1 process.
+ Turn off Pack and Hold time and pressure.
+ Make a shot in the mold and record the fill time and the hydraulic pressure at
transfer.
+ Back off the injection unit and install the purge plate if needed.
+ Make a shot in the air or through the purge plate and record the fill time and the
hydraulic pressure at transfer.
+ Insert the times and pressures into the load sensitivity equations and calculate the
results.

Fill Time mo, - Fill Time air

00
Fill Time mold

= % KPSl

Peak Hyd. PSI ,,,,- Peak Hyd. PSI air

1ooo*

Actual test O/O:

Draw conclusions:

.L..,-~--I.IL-- . .-:-- -I--&:- --..mm, ,.- I---:\ . .-- 4 n nnn

P Set up machine to run standard Decoupled II process

P Turn off pack and hold

P
' Add one second of hold time

P Set the required amount of hold pressure (usually between 40-60% of

peak pressure at transfer)

'P Weigh the part

'P Continue to add one second of hold time until the part weight stabilizes

3 Graph findings
Fountain flow experiment

+ Objective:
b To determine how plastic flows into a mold. Does it slide in or fountain flow in?
+ Equipment:
b Molding machine
b Material
b Mold with half round or trapezoidal runner
b Toilet tissue
b Grease or Vaseline

+ Procedure:
b With the mold open and machine stopped carefully place toilet tissue across the
runner area and hold in place using a touch of grease or Vaseline outside of the
runner area.
b Close the mold and inject normally.
b Observe location of toilet tissue on the shot.
b Draw conclusions
 - - - -- - - -I- - - - - -
OPENING

> TraceIDraw part in space below

P Calculate the projected area of part

,
>
I

Find required tonnage by using cavity psi or material supplier

recommendation

Area of circle = D x D x .7854 Area of square = L x W

With Cavity psi: Without Cavity psi:

Aproj X MP Aproj X Ntons/in2

2000 N = Material Supplier

Recomend.

Trace Part

Calculate max average pressure at parting line without flushing.

Clamp force in Ibs total square inches (parts and runner) =
V)
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r w
E
tu .F
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u
a
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$ $
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 rart lemperature Map

Check many points including thin and thick sections.

Date:
Machine:
Mold:
Material:
High Viscosity Material Type: Effective Viscosity High:
Low Viscosity Material Type: Effective Viscosity Low:
% Change:
DECOUPLED I1

Gate End Mold Pressure Peak High:

Gate End Mold Pressure Peak Average:
Gate End Mold Pressure Peak Low:
Gate End Mold Pressure Peak Standard Deviation:
Gate End Mold Pressure Peak Expected Variation %:

End of Cavity Mold Pressure Peak High:

End of Cavity Mold Pressure Peak Average:
End of Cavity Mold Pressure Peak Low:
End of Cavity Mold Pressure Peak Standard Deviation:
End of Cavity Mold Pressure Peak Expected Variation %:

Average of Values:
Standard Deviation:
Expected Variation %:

DECOUPLED Ill

Gate End Mold Pressure Peak High:

Gate End Mold Pressure Peak Average:
Gate End Mold Pressure Peak Low:
Gate End Mold Pressure Peak Standard Deviation:
Gate End Mold Pressure Peak Expected Variation %:

End of Cavity Mold Pressure Peak High:

End of Cavity Mold Pressure Peak Average:
End of Cavity Mold Pressure Peak Low:
End of Cavity Mold Pressure Peak Standard Deviation:
End of Cavity Mold Pressure Peak Expected Variation %:

Average of Values:
Standard Deviation:
Expected Variation %:

Standard Deviation Improvement with Decoupled Illvs. Decoupled II:

(Avg. Std. Dev. Decoupled II+ Avg. Std. Dev. Decoupled 111 x 100)

RJG, Inc.
3111 Park Drive
Traverse City MI 49686
231.947.31 11
231.946.6403 FAX
www.riqinc.com

Note: Must have Data Acquisition

DII vs D Ill Worksheet 9-24-07 Final.xls

Machine Number: Std. Cycle Tm.: Avg. Shot Weight: Ilbs.
Mold Number : Material Type: (1 gram = 0.002204623 pounds)
Number of Cavities: Material cost per Ib.: Annual Part Volume:
Machine houlry cost: Labor hourly cost:
Enter Data into blue shaded fields

Current Conditions:
(Annual Part Volume INumber of Cavities) = Cycles per Year
(Number of Cycles per Year X Standard Cycle Time) = Seconds per Year
(Number of seconds ~ .r I3600 seconds ~ ehour)
. evear r = Hours to meet An1 Volume
(Hours to meet annual volume X houlry machine rate) = I CurrentAnnual Machine cost

(Hours to meet annual part volume X houlry labor) = I CurrentAnnual Labor cost

-
Potential Savings:

New Cvcle ~ i m e : n s e c o n d s
I ~
- J r - ' .'ear (from above)
v c l e sner \(
(Number of Cycles per Year X NEW Cycle Time) = Seconds per Year
(Number of seconds ~ - r 13600 seconds per hour) =
. evear Hours to meet Annual Volume
(Hours to meet annual volume X houlry machine rate) = I NEW Annual Machine cost

(Hours to meet annual part volume X houlry labor) = I NEW Annual Labor cost

(Current Annual Machine cost - NEW Annual Machine cost) = I Annual Machine Savings
(Current Annual Labor cost - NEW Annual Labor cost) = Annual Labor Savings

(Annual Machine Savings + Annual Labor Savings) =

Parts per Day

I Total Annual cost Savings
I
Seconds Std. Cycle Number Parts
Current per day Time of Cavities per day
86,400 I X -

I P O ;; 1
Seconds
1 NEW Cycle
Time 1 1 Number
of Cavities 1 = 1 NEW Parts
per day 1
Annual Part Parts Days to
Current Volume per day Complete
1 -

u
I
Potential
I Annual Part I

I
Volume
I NEW Parts I

I I
I

I
Davs to

*Note : Parts per Day calculations assume 100% efficiency.

I

m
Machine Number:
- Std. Cycle Tm.: Avg. Shot Weight: Ilbs.
Mold Number : Material Type: (1 gram = 0.002204623 pounds)
Number of Cavities: Material cost per Ib.: Annual Part Volume:
Machine houlrv cost: Labor hourlv cost:

I
I
Enter Data into blue shaded fields

Current Conditions:
(Annual Part Volume I Number of Cavities) = Cycles per Year
(Number of Cycles per Year X Standard Cycle Time) = Seconds per Year
(Number of seconds per year I3600 seconds per hour) = Hours to meet Annual Volume
(Hours to meet annual volume X houlry machine rate) = I CurrentAnnual Machine cost

(Hours to meet annual part volume X houlry labor) = I CurrentAnnual Labor cost

Potential Savings:
New Cycle Time: =seconds
Cycles per Year (from above)
(Number of Cycles per Year X NEW Cycle Time) = Seconds per Year
(Number of seconds per year I3600 seconds per hour) = Hours to meet Annual Volume
(Hours to meet annual volume X houlry machine rate) = NEW Annual Machine cost

(Hours to meet annual part volume X houlry labor) = I NEW Annual Labor cost

(Current Annual Machine cost - NEW Annual Machine cost) = Annual Machine Savings
(Current Annual Labor cost - NEW Annual Labor cost) = Annual Labor Savings

(Annual Machine Savings +Annual Labor Savings) = I Total Annual cost Savings

Parts per Dav

Seconds Std. Cycle Number Parts
Current per day Time of Cavities per day
86,400 I X -

Seconds NEW Cycle Number NEW Parts

I IAnnual Part 1 I Parts I I Days to I I

Current Volume

I I Gained 1
NEW Parts
IP0tential 1Annual Part
Volume 1 I
1 per day 1 = I Days to
Complete 1
*Note : Parts per Day calculations assume 100% efficiency.
 now clean IS our snop-c
The 5S1sare:

Seiri: tidiness, organization. Refers to the practice of sorting through all the tools, materials,
etc., in the work area and keeping only essential items. Everything else is stored or discard-
ed. This leads to fewer hazards and less clutter to interfere with productive work.

Seiton: orderliness. Focuses on the need for an orderly workplace. "Orderly" in this sense
means arranging the tools and equipment in an order that promotes work flow. Tools and
equipment should be kept where they will be used, and the process should be ordered in a
manner that eliminates extra motion.

Seiso: systemized cleanliness. Indicates the need to keep the workplace clean as well as
neat. Cleaning in Japanese companies is a daily activity. At the end of each shift, the work
area is cleaned up and everything is restored to its place. The key point is that maintaining
cleanliness should be part of the daily work - not on occasional activity initiated when things
get too messy.

Seiketsu: standards. This refers to standardized work practices. It refers to more than
standardized cleanliness (otherwise this would mean essentially the same as "systemized
cleanliness"). This means operating in a consistent and standardized fashion. Everyone
knows exactly what his or her responsibilities are.

Shitsuke: sustaining discipline. Refers to maintaining standards. Once the previous 4S's
have been established they become the new way to operate. Maintain the focus on this
new way of operating, and do not allow a gradual decline back to the old ways of operating.