spe injection molding training presentation

Society of Plastics Engineers (SPE) - Hennepin Technical College - March 29, 2016

“Training Today’s Personnel in the Science of Plastics Processing”

Paulson Training Programs

▪Lead Provider of Scientific Plastic Processing Training

▪Established in 1977

▪Over 50,000 Trained by PTP During the Past 38 Years

▪3,000+ Companies Use Paulson Training

▪Products & Services Developed in Cooperation with Industry Experts and Product Advisory Boards

Q: Why Start Training?

A: Secret: You’ve already started

▪Lost production efficiencies (cycle time, reject rate, downtime)

▪Broken, damaged equipment▪Wasted resin▪Excessive time to 1st in-spec part▪Efficiency differences between shifts▪Cost of finding/replacing workers▪Unmotivated employees

Why Train?

Efficiency of a Molding PlantIs measured by:

Quality of Data-driven decisions:

▪ Cycle time▪ Scrap▪ Uptime/Downtime▪ Labor costs

Overall throughputConversion of raw materials into sell-able finished goods.

A sample of the practical tools

▪ Short shot analysis ▪ Balance of fill analysis▪ Gate freeze study – used for

cold gate molds mostly though some application to hot gates as well

▪ Vent viability test – This test is standard to determine if the vents are adequate.

▪ Hot spot analysis – Steel temps taken on various parts of the mold to determine balance of BTU extraction.

▪ Optimal fill rate analysis- Rheology curves etc.

The Economics of Injection Molding What is Effective Throughput?

▪Is it Cycle time?▪Low scrap rate?▪First time quality?▪Full Cavitation?▪Low labor content?▪Utilization?▪Efficiency?

YES!It’s all of these!

What do you sell?

▪Plastic parts?...........NO- What was ordered

▪Finished goods?......NO- What you produced

▪Labor?.....................NO- Cost

▪Service?..................NO- Expected

▪Efficiency?...............NO- Cost driver

▪Quality?...................NO-Expected

▪Skill/Talent?.............YES - Without it you lose

▪Time?......................YES!

Teaching Plastics Processing from the “Plastic’s Point of View”Physics doesn’t change. Plastic reacts to just four basic variables*: Heat, Flow, Pressure, and Cooling. This is the foundation for all injection molding training.*As discovered by plastic engineer and educator Donald C. Paulson.

The Four Primary Plastic Conditions

Plastic Melt Temperature

▪Frequently is not the same as the barrel temperature settings (common misconception)

▪Must be measured to actually know what effect the screw speed and back pressure are having on true melt temperature. ▪30/30 method with Pyrometer and

melt probe

A Pyrometer is a MUST have.

Plastic Flow Rate

▪The next variable we MUST control▪Plastic is a Non-Newtonian visco-

elastic material▪Faster flow rates result in lower

viscosity

Plastic Flow Rate

▪Fill time is directly related to cycle time▪Less pressure equals less stress

• Non-Newtonian characteristics of plastics

▪Fill rate control allows the machine to adapt to inherent viscosity shifts in the resin while maintaining CONTROL of the process

Plastic Pressure▪Hold/Pack pressure is how we determine

structural integrity and final dimensions of the part. • Some folks think cooling time

establishes dimensions▪Hold pressure should not be confused

with Hold time▪Sometimes we need to profile pack and

hold pressure

Relationship of Fill Rate to Pack/Hold Pressure Fill rate control helps us adapt to intrinsic

viscosity shifts in the raw material. Pack/hold time establishes the final

dimensions of the part and it’s structural integrity.

Hold time is about gate freeze. If the gate doesn’t freeze we are not in control of our process. Many times hold time can be traded for cooling time.

Plastic Cooling Rate

▪Injection molding inputs heat energy (BTU’s) into the plastic, allowing plastic to flow and pack the cavity to achieve structural integrity. Cooling removes the heat energy thus converting the plastic to a net shape. ▪The mold is a very expensive

cooling fixture

Mold Temperature Control

< 5°∆T

What really matters...▪Product efficiency should be

monitored daily▪Low product efficiency is an

operational concern▪Is it cycle time?▪Cavitation?▪Machine stoppages?▪Conduct a Root cause analysis

followed by a Corrective action plan

Root Cause analysis (link)

What you need to know

▪Annual/Monthly requirements▪Material▪Material cost▪Part weight▪Cycle time▪Number of cavities▪Projected area

▪Packaging▪Machine rate▪Labor requirement▪Special Quality criteria▪Probable efficiency

(likely scrap rate)▪Set-ups per year

The Four M’s

Causes of variation in injection molded plastic product production▪Mold ▪Machine▪Material▪Man

Industry Observations

Problem statements:

There is a shortage of skilled process technicians in the industry today. ▪Evidence of this can be found on

almost every job posting site.▪Dozens of ads for Process techs

and/or Process engineers for Injection Molding.

Benefits of Training

▪Profitability• Reduced waste, improved cycle times, fewer

mistakes and other training benefits all add up in your bottom line.

▪Productivity• Trained employees solve problems quickly

and fewer problems occur.• Trained employees make better decisions on

the production floor.

▪Knowledge• Training develops a technically competent

workforce.• Training explains the “why”, not just the

“how”.

▪Consistency• Training develops consistency of techniques -

employee to employee, shift to shift, plant to plant.“The Paulson products

are EXCELLENT!” Jim Proffitt, Rubbermaid

Why Train with Paulson?

$26,000 Reduced Cycle Times Savings$15,000 Reduce Reject Savings$ 6,000 Reduced Credits Savings$47,000 Monthly Additional Profits$564,000 Annual Additional Profits

➢ Dramatically Improved Efficiency➢ Return On Investment➢ Increased Profits

▪Downtime Reduced by 32%▪Mold Change Time is 10%

Lower▪Revenue/Machine Hour

Improved 35%▪Scrap Parts Down 8% and

Production Up 15%

SkillBuilder™

World’s leading injection molding machine simulator

SkillBuilder Benefits▪Employees practice molding in

a safe environment and are not tying up valuable machine time, materials and resources.

▪Uses interactive training platform to improve processing knowledge - quickly. One hour of simulation practice is equal to 5 actual machine hours!

▪“Free Mold” for learning problems solving techniques and optimizing cycle times.

More SkillBuilder Benefits▪Provides structured tutorial to see

the effects of each machine control on melt temperature and part dimensions.▪Develops understanding of plastic

behavior under processing conditions.▪Reinforces the information

presented in training modules.▪Turns theory of processing into

reality.▪Turns knowledge into skill.▪Automatic record keeping of all

training activities

SkillBuilder Connects the Classroom with the Production Floor

What You Can Do With SkillBuilder

MORE Interactive Lab Lessons

Optimizing Machine Control Settings with SkillBuilder

Injection Molded Part Problems and Solutions

with SkillBuilder1. Optimizing the Melt

Temperature with an Amorphous Plastic

2. Optimizing the Melt Temperature with a Crystalline Plastic

3. Finding the Minimum Fill Time Required

4. Optimizing Part Dimensions5. Optimizing Part Weight6. Achieving the most efficient

Cycle Time

1. Getting Rid of Burnmarks

2. Molding to Precise Dimensional Tolerances

3. Controlling Flash on a Molded Part

4. Solving Sinkmark Problems

5. Identifying and Solving Voids in Molded Parts

6. Weldline Formation and Possible Solutions

Paulson Products and Services

“Great products, easy to use and dynamic 3-D graphics!” Ken Lewis, S&L Plastics

▪ Injection Molding Process Training

▪ Injection Molding Simulation

▪ Thin Sheet Thermoforming

▪ Twin Screw Compounding

▪ Sheet Extrusion Technology

▪ Extrusion Blow Molding

▪ Products in Multiple Languages

Injection Molding

▪Basic Molding Machine Operations

▪Practical Injection Molding

▪Optimizing Machine Control Settings

▪Injection Molded Part Problems & Solutions▪Hot Runner Molding Solutions

▪Implementing DECOUPLED MOLDING

▪Design of Experiments

▪SPC for Injection Molding

▪Efficient Mold Setting

▪Understanding Materials for Profitable Molding▪Plastics Drying Technology

“BESPAK has had a very positive experience using Paulson Interactive Training Programs. Not only all of our molding personnel, but many of our office & support staff have completed the training, which has given them greater insight into our primary manufacturing process of injection molding.” David Hepbrun, BESPAK

SM

Extruder Operationand Control Single Screw

1. The Single Screw Extruder: Parts and Operation2. The Structure of Plastic Raw Materials3. The Characteristics of Plastics for Extrusion4. Effects of Pressure, Temperature and Flow5. Optimizing Extruder Controls – Part 16. Optimizing Extruder Controls – Part 27. Safety, Pre-Start and Start-Up Procedures8. Steady-State Operation, Shutdown and

Maintenance Procedures9. Single Screw Extruder Troubleshooting

Thin Sheet Thermoforming

▪ Optimizing operating controls

▪ Safety around the thermoforming machinery

▪ Thermoforming for maximum efficiency and profit.

Operation of the machinery used in thermoforming

The function of each component of thermoforming line

Plastic behavior during the thermoforming process

Sheet extrusion fundamentals,

Extrusion Blow Molding Technology

Recognize processing conditions that affect quality

Analyze and solve practical blow molding problems

Develop a working knowledge of blow molding machinery

Evaluate and improve operating procedures

Compounding with the Twin Screw Extruder

Detailed video explanation of what is going on inside the extruder, and how control setting adjustments affect the plastic and output.

Describes optimal machine-running procedures with proven employee-learning models for more thorough, better-retained learning

Teaches in-depth operating skills for increased efficiency and productivity

Develops insight for quicker, more accurate troubleshooting and problem resolution

Strengthens process control skills for greater productivity and less waste

Sheet Extrusion Technology

▪ The Sheet Extrusion Line: Parts and Operation

▪ Sheet Extrusion Dies

▪ Controlling Plastic Flow in the Die

▪ Plastic Behavior in the Sheet Extrusion Line

▪ Pre-Start, Start-up, and Steady-State Operating Procedures

▪ Safety and Shutdown Procedures

▪ Troubleshooting the Sheet Extrusion Line

The Paulson Difference

“We’re pleased to add Paulson Training Programs to our group of affiliate partners. They have a well-established reputation due to top quality products and through years of providing advances in training such as their injection molding simulator, SimTech.” Bill Gruber, Concentric Custom Services

▪ 24/7 Cross platform deliverability. Phone, tablet, computer. Anytime, anywhere

▪ Innovative injection molding simulation teaching tools

▪Paulson Plastics Academy Tech Center

▪Seminars at your plant in Injection Molding, Thermoforming, Extrusion Blow Molding

Paulson Plastics AcademySeminars from the Paulson Plastics Academy teach the fundamentals of plastics engineering and scientific molding. All classes are led by expert instructors who bring to life the basics and advanced topics of injection molding.

Paulson Plastics Academy Seminar Titles ProMolder 1 ProMolder 2 Data-Driven Molding

Module 1 Set-Up Module 2 Process Module 3 Certification

Mold Design Fundamentals Managing a Molding Plant ProEx 1 ProEx Blow Molding

Paulson Plastics Academy Technical Center

Offering a whole new learning experienceLocated in sunny Florida, the Tech Center offers:

A dedicated, 9,000 sq. ft. injection molding training facility

Expert injection molding instructors Four injection molding machines for hands-

on machine time Multiple Classrooms Six-station computer lab, loaded with

Paulson courseware & simulator QC Lab

All-in-One Training Solution

Online

• ONLINE-TRAININGAnytime, anywhere

• REAL-TIME INTERACTIVEMolding simulation

OnSite• CUSTOM ONSITE

Customized training at your facility

HandsOn

• MULTI-CITY SEMINAR TRAININGHands-on and in person

• DEDICATED TRAINING CENTERClassrooms & Machines

Skilled People Come From Paulson

▪New Hires▪Machine Operators▪Process Engineers▪Supervisors▪Part Handlers▪Technicians▪Production Management▪CEOs

Partial List of our 3,000+ Clients

Winners Powered by Paulson

2005 - U.S. Farathane Corp.

2004 - Miniature Precision Components Inc.

2002 - (Tie) Tech Group Inc. & Precise Technology Inc.

2001 - Cascade Engineering Inc.

2000 - Tessy Plastics Corp.

1997 - Nypro Inc.

2015 – Evco Plastics

2014 - Stihl Inc.

2013 - Tech Molded Plastics Inc.

2012 - Hoffer Plastics Corp.

2011 - Steinwall Inc.

2010 - Plastikos Inc.

2009 - GW Plastics Inc.

2008 - Plastic Components Inc.

2007 - Innovative Injection Technologies Inc.

2006 - Mack Molding Co.

Plastics News – Processor of the Year

Industry Alliances and Partners

THANK YOU Society of Plastics Engineers, SPE

Hennepin Technical College and all attendees for your time today!

www.PaulsonTraining.comTed Chryzanowski

800-826-1901tedc@paulsontraining.com

Powerful Training. Proven Results.