scholarly journals Penerapan Metode Six Sigma pada IKM Manufaktur Industri Pendukung (Supporting Industry) untuk Meminimalkan Jumlah Produk Cacat

2021 ◽  
Vol 20 (2) ◽  
pp. 104-113
Author(s):  
Cucu Wahyudin ◽  
Agung Apriliandi
Keyword(s):  
Injection Molding ◽  
Six Sigma ◽  
Cooling Time ◽  
Business To Business

Industri pendukung merupakan industri yang membuat barang dan jasa, menjual ke pasar bebas atau ke industri lain untuk mendukung produk akhir yang memiliki nilai tambah. Karakteristik industri pendukung adalah business to business, sehingga efisiensi proses produksi menjadi kunci daya saingnya. Proses produksi yang efisien dapat meminimalkan cacat sehingga biaya produksi dapat diperkecil. Penelitian ini mengkaji penerapan metode six sigma di industri pendukung yang memproduksi alat peraga pendidikan. Penelitian dilakukan di perusahaan dengan tingkat kecacatan hingga 8,10 % pada produk cermin kombinasi. Nilai sigma produk tersebut sebesar 3,71 yang menunjukan bahwa peluang untuk melakukan perbaikan proses masih sangat terbuka. Perbaikan proses dilakukan dengan menerapkan tahapan perbaikan DMAIC (Define–Measure–Analyze–Improve-Control). Pada tahap define diketahui yang menjadi cacat dominan adalah jenis cacat Shrink Mark, yaitu sebesar 31% dari keseluruhan jenis kecacatan produk. Penyebab terjadinya cacat tersebut adalah tidak adanya nilai setting parameter yang digunakan secara konsisten pada mesin injection molding. Melalui serangkaian eksperimen, penelitian ini menentukan nilai setting parameter yang dapat meminimalkan cacat jenis shrink mark. Faktor setting parameter terpilih adalah cooling time dan holding pressure dengan nilai masing masing selama 20 detik dan 105 MPa. Reject rate produk cermin kombinasi berhasil diminimalkan dan nilai sigma meningkat menjadi 4,13.

scholarly journals Improving Cooling Performance of Injection Molding Tool with Conformal Cooling Channel by Adding Hybrid Fillers

Polymers ◽  
2021 ◽  
Vol 13 (8) ◽  
pp. 1224
Author(s):  
Chil-Chyuan Kuo ◽  
Wei-Hua Chen
Keyword(s):  
Thermal Conductivity ◽  
Injection Molding ◽  
Cooling Time ◽  
Performance Ratio ◽  
Cooling Efficiency ◽  
Cooling Channel ◽  
Conformal Cooling Channel ◽  
Conformal Cooling ◽  
Fused Deposition ◽  
Silicone Rubber Mold

Silicone rubber mold (SRM) is capable of reducing the cost and time in a new product development phase and has many applications for the pilot runs. Unfortunately, the SRM after injection molding has a poor cooling efficiency due to its low thermal conductivity. To improve the cooling efficiency, the thermal conductivity of the SRM was improved by adding fillers into the SRM. An optimal recipe for fabricating a high cooling efficiency low-pressure injection mold with conformal cooling channel fabricated by fused deposition modeling technology was proposed and implemented. This study proposes a recipe combining 52.6 wt.% aluminum powder, 5.3 wt.% graphite powder, and 42.1 wt.% liquid silicon rubber can be used to make SRM with excellent cooling efficiency. The price–performance ratio of this SRM made by the proposed recipe is around 55. The thermal conductivity of the SRM made by the proposed recipe can be increased by up to 77.6% compared with convention SRM. In addition, the actual cooling time of the injection molded product can be shortened up to 69.1% compared with the conventional SRM. The actual cooling time obtained by the experiment is in good agreement with the simulation results with the relative error rate about 20%.

The Use of Advanced Aluminum Alloys for Enhanced Productivity in Plastic Injection Molding

2000 ◽  
Author(s):  
Jim Nerone ◽  
Karthik Ramani
Keyword(s):  
Aluminum Alloys ◽  
Injection Molding ◽  
Wall Thickness ◽  
Simulation Software ◽  
Cooling Time ◽  
Coolant Temperature ◽  
Steel Mold ◽  
Cooling Channels ◽  
Injection Molding Simulation ◽  
Increased Strength

Abstract New aluminum alloys, QC-7® and QE-7®, have thermal conductivities four times greater than traditional tool steels, and have significantly increased strength and hardness compared to traditional aluminum materials. Molds were constructed of P-20 tool steel and QE-7® aluminum and were used to provide experimental data regarding thermal mold characteristic and confirm injection molding simulation predictions using C-Mold®. The relationships between cooling time reduction (using aluminum alloys) and polymer type, cooling channel depth, part wall thickness, and coolant temperature were explored both experimentally and using simulation software. It was shown that the potential reduction in cooling time varied from 5% to 25%. The most significant percentage improvements were observed in parts with part wall thickness of 0.05″ to 0.10″ and in molds with cooling channels at a depth ratio (D/d) of 2.0. The thermal pulses in the steel mold 0.10″ from the surface were approximately 63% larger than in aluminum mold.

THERMAL ANALISIS INJECTION MOLDING PADA COVER AIR FLOW TERHADAP SHORT MOLD DEFECT

2021 ◽  
Vol 26 (2) ◽  
pp. 103-110
Author(s):  
Muhammad Yusuf Nurfani ◽  
Irvan Septyan Mulyana
Keyword(s):  
Injection Molding ◽  
Air Flow ◽  
Cooling Time ◽  
Short Shot

Plastik Injection Molding (PIM) merupakan proses produksi pembentukan material plastik dari material resin berbentuk butiran yang digunakan dalam membuat suatu komponen manufaktur. Defect atau kecacatan yang umumnya terjadi pada plastik injection molding yaitu short mold yaitu kondisi dimana part yang dihasilkan tidak terisi material plastik secara sempurna. Pada penelitian membahas tentang analisa panas pada cover air flow terhadap short mold defect. Metode yang digunakan adalah metode perhitungan actual dan analisa aktual terhadap part injection kemudian membandingkan hasil dari variasi suhu. Material yang digunakan dalam penelitian ini adalah Polypropylene (PP) dengan grade M560 yang dimasukan kedalam injection molding dengan tekanan 96 Mpa. Suhu yang akan dianalisis yaitu 130̊C dengan cooling time 15 second , suhu 150̊C cooling time 19 second dan suhu 170̊C cooling time 23 second. pada barrel. Hasil penelitian ini menunjukan temperatur 170̊C dengan cooling time 23 detik dapat mengatasi masalah short shot pada cover air flow pada saat proses injection part.

OPTIMASI PRODUKSI TUTUP BOTOL 500 ml PADA PROSES INJECTION MOULDING MENGGUNAKAN METODE RESPONSE SURFACE

ROTOR ◽  
2017 ◽  
Vol 10 (1) ◽  
pp. 36
Author(s):  
Kurniawan Purnama Putra ◽  
R. Koekoeh R. W.
Keyword(s):  
Injection Molding ◽  
Response Surface ◽  
Cycle Time ◽  
Injection Moulding ◽  
Plastic Material ◽  
Cooling Time ◽  
Mathematical Methods ◽  
Nozzle Temperature ◽  
Pressure Nozzle ◽  
Plastic Pellets

Injection molding is one of the most common operations and versatile for mass production of complex plastic components. Injection molding is a process of plastic forming into a desired shape by means of pressing molten plastic into a space (cavity). Injection molding has a multi-step process, starting from inserting plastic pellets into the hopper, then plastic pellets into barrels / heating which makes the plastic material is melted. Melting plastic material is driven by the rotation of the screw, so that the flow to the nozzle, and then toward the sprue, runner, gate and into the cavity. Then the material present in the cavity will be retained within the mold under a certain pressure (holding pressure) to keep no shringkage when the product cooling process (cooling).The purpose of this study was to obtain the optimization of the cycle time and the percentage of production reject the bottle cap 500 ml in PT Berlina Tbk. The method used for this research is the method of response surface analysis, method surface respone is statistical and mathematical methods used to examine the relationship between one or more variables with the qualitative form of the response variables that aims to optimize and develop the response in an experiment. The data is optimized using Minitab software 16 produces an output response parameter setting optimization to inject pressure, nozzle temperature and cooling time. From the data analysis using the software Minitab 16 is obtained from the optimum situation results generated under conditions injection amounting to 1420 bar pressure; nozzle temperature at 264.7912 ° C; and the cooling time of 14.08 seconds. In this state of production can be increased by 10.836%. From the state of the optimum cycle time generated is 27.9161 seconds, net produced according to the standard that is 33.5820 grams and reject percentage the resulting is 11.11%. With a cycle time 27.9161 seconds with a net according to the standard and the percentage of rejects decreased 3.89%, the resulting product amounts to ± 15,517 /shift or up approximately 10.836%. The amount is based on the number of products produced in the cycle time previous of 30 seconds to produce ± 14,000 /shift. Keywords: Injection moulding, box-benhken design, Response surface methodology

Determination of ejection temperature and cooling time in injection molding

1992 ◽  
Vol 32 (3) ◽  
pp. 191-197 ◽  
Author(s):  
Chi J. Yu ◽  
J. E. Sunderland
Keyword(s):  
Injection Molding ◽  
Cooling Time

Reduction of Rejection Rate for High Gloss Plastics Product Using Six Sigma Method

2014 ◽  
Vol 606 ◽  
pp. 141-145
Author(s):  
Che Ku Abdullah Che Ku Kairulazam ◽  
M.I. Hussain ◽  
Zuraidah Mohd Zain ◽  
Nabilah A. Lutpi
Keyword(s):  
Injection Molding ◽  
Six Sigma ◽  
Rejection Rate ◽  
Injection Molding Process ◽  
Molding Process ◽  
Sigma Level ◽  
Potential Factors ◽  
High Rejection Rate ◽  
And Control ◽  
Plastic Injection

High gloss plastics part in injection molding industries were widely used in Malaysia. However the high rejection rate in this industries were major problem affecting the economic aspects. Therefore this paper presents an approach of implementing six sigma method to reduce the rejection rate in a plastic injection molding process for high gloss plastics part. Define, Measure, Analyze Improve and Control (DMAIC) methodology was applied as basis of the study. By using current process, the average of rejection is 40.6% and the aim of this study is to reduce the rejection rate to less than 10 % . All potential factors were taken into account to identify the significant factors. The improvement process was made base on the analysis output. This study was successful with increment in sigma level from 1.74 σ to 3.00 σ. .

scholarly journals ANALISIS PERBAIKAN KUALITAS INJECTION PART DENGAN PENDEKATAN LEAN SIX SIGMA

2020 ◽  
Vol 1 (01) ◽  
pp. 79-90
Author(s):  
Miftakul Huda
Keyword(s):  
Injection Molding ◽  
Six Sigma ◽  
Rejection Rate ◽  
Lean Six Sigma ◽  
Factorial Experiment ◽  
Full Factorial Experiment ◽  
Yield Rate ◽  
Sigma Level ◽  
And Control ◽  
Full Factorial

Lean Six Sigma is a collective approach, which uses various techniques and tools for quality improvement. Here, Lean Six Sigma methodology was applied to a small injection molding unit (which can be taken as representative of small and medium-size industries) manufacturing casing of electronics part. The DMAIC (Define, Measure, Analyze, Improve and Control) approach of Lean Six Sigma was applied to reduce the rejection rate of the casing (child part of an electronic product) by changing setting parameters: mold temperature, injection pressure and injection speed in the injection mold process. The statistical techniques such as DOE full factorial experiment, and process capability analysis were done to finding the process capability before and after the Lean Six Sigma implementation. After implementing the Lean Six Sigma DMAIC approach it was found that injection molding firms can increase their profit by increase yield rate and deleting rejection rate of casing part. Lean Six Sigma implementation increase the process sigma level from 4,3σ to 4,7σ by a reduction in casing flow mark variation and transparency. This increase in sigma level will give defect cost reduction to the industry which is a good figure for such an industry.  Abstrak Lean Six Sigma adalah pendekatan kolektif, yang menggunakan berbagai teknik dan alat untuk peningkatan kualitas. Di sini, metodologi Lean Six Sigma diterapkan pada unit injection molding kecil (yang dapat dianggap mewakili industri ukuran kecil dan menengah) manufaktur casing part. Pendekatan DMAIC (Define, Measure, Analyze, Improve and Control) Lean Six Sigma diterapkan untuk mengurangi tingkat penolakan casing part (bagian anak dari produk elektronik) dengan mengubah tiga setting parameter: suhu mold, tekanan dan kecepatan injection dalam proses cetakan injeksi. Teknik statistik seperti DOE full factorial experiment,dan  analisis kemampuan proses dilakukan untuk menemukan kemampuan proses sebelum dan sesudah implementasi Lean Six Sigma. Setelah menerapkan pendekatan Lean Six Sigma DMAIC ditemukan bahwa perusahaan injection molding dapat meningkatkan keuntungannya dengan menaikan yield rate dengan mengendalikan tingkat penolakan casing part. Implementasi Lean Six Sigma meningkatkan tingkat sigma proses dari 4,3σ menjadi 4,8σ dengan mengurangi variasi flow mark dan transperancy. Kenaikan tingkat sigma ini akan memberikan pengurangan biaya akibat cacat ke industri yang merupakan contoh yang baik untuk industri semacam ini.                                                                                                                                                

scholarly journals Design, Optimization and Validation of Conformal Cooling Technique for Additively Manufactured Mold Insert

2021 ◽  
Vol 2070 (1) ◽  
pp. 012225
Author(s):  
G.Dongre Ganesh ◽  
S.Chaitanya Sarang ◽  
M.Jonnalagadda Sai
Keyword(s):  
Injection Molding ◽  
Mold Insert ◽  
Cooling Time ◽  
Cyclic Process ◽  
Conformal Cooling ◽  
Cooling Circuit ◽  
Cycle Times ◽  
Cooling Channels ◽  
Conventional Cooling ◽  
Time Required

Abstract Injection molding is a cyclic process comprising of cooling phase as the largest part of this cycle. Providing efficient cooling in lesser cycle times is of significant importance in the molding industry. Conformal cooling is a proven technique for reduction in cycle times for injection molding. In this study, we have replaced a conventional cooling circuit with an optimized conformal cooling circuit in an injection molding tool (mold). The required heat transfer rate, coolant flow rate and diameter of channel was analytically calculated. Hybrid Laser powder bed fusion technique was used to manufacture this mold tool with conformal channels. The material used for manufacturing mold was maraging steel (M300). Thermal efficiency of the conformal channels was experimentally calculated using thermal imaging. Autodesk MoldFlow software was used to simulate and predict the cooling time required using conformal cooling channels. The results showed a decrease in cooling time and increase in cooling efficiency with the help of conformal cooling in additively manufactured mold insert.

scholarly journals PENGARUH INJECTION TIME DAN BACKPRESSURE TERHADAP CACAT PENYUSUTAN PADA PRODUK KEMASAN TOPLES DENGAN INJECTION MOLDING MENGGUNAKAN MATERIAL POLISTYRENE

2017 ◽  
Vol 4 (3) ◽  
pp. 15
Author(s):  
U. Wahyudi
Keyword(s):  
Quality Control ◽  
Injection Molding ◽  
Injection Pressure ◽  
Cooling Time ◽  
Injection Time ◽  
Injection Speed

Produk kemasan kue atau toples adalah produk rumah tangga yang sangat dibutuhkan untuk menaruh berbagai macam-macam kue kering, Produk plastik ini terdiri dari badan dan tutup, kedua komponen ini pada saat dirakit memerlukan kepresisian yang lumayan bagus oleh karena material yang digunakan plastik, maka faktor penentuan penyusutan(shrinkage) memegang peranan sangat penting pada saat dicetak dengan mesin injection molding yang menggunakan material polistyrene. Pada saat produksi pernah terjadi kegagalan produk fitting terlalu kencang dan ada juga fitting yang kendor antara tutup dengan badan akibatnya produk tidak lolos produksi oleh quality control. Didalam tugas akhir ini penulis melakukan langkah-langkah bagaimana teknik menganalisa cacat penyusutan (shrinkage) material plastik terutama di khususkan material polystyrene dimulai dari proses injection molding lalu diambil sampel produk dengan tingkat pengujian yang berbeda lewat settingan parameter. Dengan waktu injeksi dan backpressure yang berbeda-beda akan menghasilkan ukuran produk dan nilai shrinkage yang berbeda pula. Nilai temperatur leleh yang baik digunakan untuk material polistyrene dengan ketebalan produk kemasan toples 0,75 mm, diameter produk 140,94 mm dan tinggi 58,29 mm. berkisar antara 2400C – 3100C. Cacat penyusutan pada material polystyrene pasti ada walaupun tidak sebesar pada material lain seperti PP dan LDPE dan bisa diminimalkan dengan setting parameter proses yang bagus. Nilai shrinkage yang baik dan ideal dan sesuai standar terjadi pada settingan backpressure 30 kgf/cm² dengan waktu injeksi yaitu 2 detik. Dengan  parameter yang konstan, mulai dari injection speed 120 cm/s, 65 cm/s. Injection pressure 1400 kgf/cm² dan pack pressure 1200 kgf/cm², pack time 0,5 sec, Shot size 55 mm, kemudian cooling time 2 detik dengan temperatur mold 600 C.

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