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Custom Injection Moliding and the Lean Manufacturing Process

Custom injection molding has always been a fast moving, chaotic, and challenging business. It also has a high potential for profit, even today, despite the international competition and tight margins. You want to succeed, you see the possibilities, but the global pricing and high expenses make it very difficult.

Plastic injection molders are in the almost ideal business to benefit from the lean manufacturing process. If you embrace the entire concept and do not cherry pick the parts that are quick and easy, you will most certainly experience improvements in your operation.

The lean manufacturing process is an integrated approach to reducing waste. It could be time or material or anything else; waste is waste and waste equals money in business. It requires a shift in thinking to approach efficiency from this vantage point, rather than always striving to do more, do it faster, do it better.

Six Sigma

Implementing six sigma requires that management is dedicated to making it work in the long run. Employees are often cynical toward new programs because, in the past, many programs amounted to little more than slogans and banners.

Using a six sigma consulting firm is a good idea, once you have educated yourself in the basic principles. The time and expense of hiring an outside consultant will pay off handsomely over time. If you have the personnel to mange your six sigma implementation in-house that is even better; though they will certainly need some additional training.

5S

5S training will give you a huge boost in your lean manufacturing process. This is because the results are so immediate and visible. Everyone likes having the tools they need, the materials in the proper place with labels, and a general atmosphere of everything in it’s place.

It is relatively easy to get your employees to go along with a 5S program. Within a week you will see changes in your production area and the attitude of everyone. Find the key people, train them, give them the authority and communicate with the entire workforce in order to avoid grumbling and confusion.

Kaizen

When you conduct a kaizen blitz, or event, you pick an area or a process and focus exclusively on it. This is a great way to make progress and get people involved because it is by nature short and intense. It is a bit like cleaning up you kitchen before your mother-in-law comes for a visit! You hyper-focus on one area after another until the whole is done.

One drawback though with a kaizen blitz is that it can be mistakenly understood to be the entire process. It is just a component and it should be regarded as such. If it becomes the program, you will not really change the culture or become much more efficient in your operation.

How to get going

It is a good idea to talk to successful shop owners who have benefited from the lean manufacturing process. You will find them enthusiastic and quite willing to open up, for the most part. You should also read and gather information so you can make wise decisions rather than totally rely on the opinion of a consultant. In the end, you will certainly need outside help, but you also need a thorough understanding of the process yourself.

Randy Hough
Plastic Injection Mold Maker
http://whatisleanmanufacturing.com

“You know Dad, I’ve been thinkin’, one is a lot more than zero!” my son, Thomas, age 5.

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Custom Injection Molding Process and advantages

Injection Molding is a process by which most plastic solid materials are produced. We have dedicated and experienced designer’s team having knowledge in tool design, custom injection molding and designing of core cavities for dies and molding.
Custom injection molding has always been a fast moving, disordered and demanding business. Now a day, despite the competition and tight margins it also has a potential for profit. You want to succeed, you see the possibilities, but the global pricing and high expenses make it very difficult.

What is the process of Injection molding?

The first step is plastic heated till it melts during the process of plastic injection molding. The mold can make by using any metal like steel or aluminum. The molten form is then allowed to cool down and set into a solid form. The plastic material thus formed is then retrieved out of the mold.

Next is the actual injection of the melted plastic. The plastic usually begins this process as pellets that are put into a large hopper. The pellets are then fed to a cylinder; here they are heated until they become molten plastic that is easily forced into the mold. The plastic stays in the mold, where it is being clamped under pressure until it cools.

The next couple of steps consist of the dwelling phase, which is basically making sure that all of the cavities of the mold are filled with the melted plastic. After the dwelling phase, the cooling process begins and continues until the plastic becomes solid inside the form. Finally, the mold is opened and the newly formed plastic part is ejected from its mold. The part is cleaned of any extra plastic from the mold.

The Factors involved in the Custom Injection Molding process are :

•    The pressure of injection can be changed to change the hardness of the final product.
•    The thickness of the mold also governs the quality of the article produced.
•    The temperature for melting and cooling determine the quality of the plastic formed.

Advantages of Custom Injection Molding

There are so many advantages of using custom injection molding process. The major advantage of injection molding is that it is very reliable and cost-effective. Also, this process produces smooth and finished products that require no further finishing.

•    Substantial cost savings due to availability of skilled 3D professionals at lower cost
•    High Quality standards are maintained
•    Quick Turn around Time
•    Reduces capital costs of infrastructure
•    Attractive Advanced technology
•    Increased capacity for business expansion and diversification
•    Improve employee satisfaction with higher value addition jobs
•    Allows you to focus on core business
•    Saving in human resources

To get more information about injection molding, you may visit us at http//www.mechanical3dmodelling.com. If you have query about Custom Injection molding, please email us at: info@mechanical3dmodelling.com

custom plastic injection molding

Injection mildew design is an element of the fast-paced world of injection molding. When as a mildew designer, you must be able to think about new techniques of making things, and be flexible and ready to learn new technologies.It might look easy due to the powerful CAD programs, but in actual fact these programs are merely the instruments to help prepare your design. In the field of injection mold design you regularly must develop new and original techniques of plastic molding.

what is a normal day like for a mold designer? Mold designers and mildew makers work closely together. This is patently for the explanation the mildew maker will be using the design to build the mildew. Mold makers and mould designers have a really similar daily schedule, though mould makers seem to work longer hours.Generally, a plastic mould designer works all day at his computer using some really sophisticated mildew design platforms. There are a lot of top-end design programs,eg SolidWorks, MasterCam, AutoCad, Unigraphics, and lots more. These applications enable the designer to rapidly look after details that previously took days of hand drawing.

Very often the mould designer will be required to communicate with the various mold makers, CNC programmers, WEDM operators, etc.. The mould designer must be ready and able to communicate, if he is to achieve success. Very often injection mold designers work less hours than their mould maker opposite numbers. It’s also common for mould designers have a shop background and help out in the mould making shop also. This is especially true if there’s a deceleration in design and plenty of work in the store.

How to turn an injection mold designer? Fundamentally, there are 2 trails in the United States. One path is to work as a mould maker and later move into the design area. The other trail is to attend a college or university to become qualified. Both approaching are quite common.Since so many plastic molding designers come from a mildew making background, they are able to bring practical experience to the job. This is especially useful to provide a realistic approaching to mold design. There’s nothing quite like practical experience!

If you are looking into purchasing Custom Injection Molding or would like a Injection Mold Design, then the above site is the place to visit.

because we live and operate in a world economy, it isn’t even a prerequisite to work in the same country as the mould maker, though it is simpler if you do. There are many mold designers who independent out of their own small office and are quite happy doing so. This is a workable alternative for the right person.Conclusion Injection mildew design is a highly respected occupation with really low unemployment and good pay. Most mildew designers have secure jobs that provide a cosy living with a minimum of occupational dangers, compared to other roles. It’s also very possible to work as a freelancing mold designer and have substantial freedom of trend.
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