scholarly journals Overall Equipment Effectiveness to Increase Productivity of Injection Molding Machine: A Case Study in Plastic Manufacturing Industry

2021 ◽  
Vol 12 (1) ◽  
pp. 53-64
Author(s):  
Sunadi Sunadi ◽  
Humiras Hardi Purba ◽  
Else Paulina
Keyword(s):  
Injection Molding ◽  
Manufacturing Industry ◽  
Positive Impact ◽  
Molding Machine ◽  
Injection Molding Machine ◽  
Effect Analysis ◽  
Pareto Chart ◽  
Increase Productivity ◽  
Cause And Effect Diagram

In line with the unstable market conditions in Indonesia, especially the plastic manufacturing industry, the companies need to be well prepared to survive. There were two research goals. First, it was to find out why the Overall Equipment Effectiveness (OEE) rate at the company did not meet the expected standard. Second, it was to determine what improvement should be made to increase the OEE for the machine. The research applied a case study in one of the plastic manufacturing industries located in Tangerang, Indonesia. It focused on the performance of Toshiba injection molding machine number 42/IS 450 GSW. The analysis was performed by applying Failure Mode and Effect Analysis (FMEA) with support from other tools such as Pareto chart, Cause and Effect Diagram (CED), and six big losses. By following the whole framework of the research, it finds causes of why the OEE does not meet the target. Then, from the results, it can be concluded that the implementation of the methods has a positive impact on the company. The OEE rate increases from an average of 26,43% to 78,87%. It means the OEE rate has achieved the company target of 75%.

Energy and GHG Emissions Assessment in a Plastic Injection Process at Machine Component Level: A Case Study of ABS Plastic Part Produced in a Hybrid Injection Molding Machine

2017 ◽  
Author(s):  
Javier Ávila ◽  
Vicente Borja ◽  
Marcelo López-Parra ◽  
Alejandro C. Ramírez-Reivich
Keyword(s):  
Injection Molding ◽  
Ghg Emissions ◽  
Energy Usage ◽  
Molding Machine ◽  
Injection Molding Machine ◽  
Energy Assessment ◽  
Injection Process ◽  
Hybrid Injection ◽  
Plastic Injection

In this article a GHG and energy analysis for the plastic injection process of an ABS medium sized injected part carried out in a hybrid injection molding machine is reported. A power consumption process pattern for an ABS medium-size part is defined as well as the energy usage of components, the energy used for the injection process is calculated for the injection cycle and for the process setup. The reported study includes a hybrid machine analysis working under an electric network that relies mainly on thermoelectric energy generation. The GHG emissions assessment was estimated using the 2015 emission factor applied for Mexico. The results provide new experimental data for ABS plastic injected parts in hybrid injection machines. This paper describes the outcomes of a GHG emissions and energy assessment for an ABS medium-sized injected part carried out in a HIMM at UNAM. The approach followed by the authors in this assessment was aimed at providing information about the energy usage and GHG emissions for the process and the part. The main contribution of this paper is the insight related to energy usage indicators in the process, the energy usage and the GHG emissions within components. The product used as a case study and the results of its GHG emissions and energy assessment are presented.

Development of a Finite Model for Controlling a Mold’s Open/Close Process in an Injection Molding Machine

2011 ◽  
Author(s):  
M. F. Alzoubi ◽  
Ma’moun Abu-Ayyad
Keyword(s):  
Injection Molding ◽  
Positive Impact ◽  
Cycle Duration ◽  
Finite Model ◽  
Molding Machine ◽  
Movable Part ◽  
Time Duration ◽  
Element Analysis ◽  
Injection Molding Machine ◽  
Sampling Instant

This paper presents a unique approach for integrating a finite element analysis (FEA) model using a dynamic explicit of Abaqus with a nonlinear process of the mold’s open/close phase in an injection molding machine. This opening/closing phase is considered to have one of the highest impacts on reducing an overall cycle duration since it has no impact on the final part quality. Reducing the overall cycle duration has a big positive impact on productivity and enhancing efficiency of the manufacturing processes of injection molding systems. Therefore, one of the objectives of the injection molding manufacturers is increasing efficiency by reducing the time duration of this phase to a possible minimum. In this work, a 3-dimensional (3D) solid model of the mold, toggle mechanism, and hydraulic cylinder were developed and then superimposed with Abaqus software to animate the motion of the movable part of the mold. The position of the movable part of the mold is traced and used as a controlled variable while the inputted force and initial velocity were considered as the manipulated variables. The innovation of this strategy is that the controller structure uses the nonlinear model to update the process variables at every sampling instant while the closed-loop control is executed. This allows the determination of the plant’s variables resulting in a new set of the controller parameters with every sampling instant.

scholarly journals Application of Neural Networks to Explore Manufacturing Sales Prediction

2019 ◽  
Vol 9 (23) ◽  
pp. 5107 ◽  
Author(s):  
Po-Hsun Wang ◽  
Gu-Hong Lin ◽  
Yu-Cheng Wang
Keyword(s):  
Neural Networks ◽  
Injection Molding ◽  
Manufacturing Industry ◽  
Molding Machine ◽  
Injection Molding Machine ◽  
R And D ◽  
Sales Prediction ◽  
Machine Industry ◽  
The Impact ◽  
Plastic Injection

Manufacturing sales prediction is an important measure of national economic development trends. The plastic injection molding machine industry has its own independent R and D energy and mass production technology, with all products sold globally through international brands. However, most previous injection molding machine studies have focused on R and D, production processes, and maintenance, with little consideration of sales activity. With the development and transformation of Industry 4.0 and the impact of the global economy, Taiwan’s injection molding machine industry growth rate has gradually flattened or even declined, with company sales and profits falling below expectations. Therefore, this study collected key indicators for Taiwan’s export economy from 2008 to 2017 to help understand the impact of economic indicators on injection molding sales. We collected 35 indicators, including net entry rate of employees into manufacturing industries, trend indices, manufacturing industry sales volume indices, and customs export values. We used correlation analysis to select variables affecting plastic injection machine sales and artificial neural networks (ANN) were applied to predict injection molding machine sales at each level. Prediction results were verified against the correlation indicators, and seven key external economic factors were identified to predict accurate changes in company annual sales prediction, which will be helpful for effective resource and risk management.

scholarly journals PLANNING AND SCHEDULE OF MAINTENANCE WORKS FOR INJECTION MACHINES

2021 ◽  
Vol 1 (2) ◽  
pp. 41-51
Author(s):  
Ramona-Iuliana Popa ◽  
◽  
Maria Catana ◽  
Gabriel Cimpoesu ◽  
Lucian Burlea ◽  
...  
Keyword(s):  
Injection Molding ◽  
Machine Tools ◽  
Manufacturing Systems ◽  
Molding Machine ◽  
Injection Molding Machine ◽  
Planning And Scheduling ◽  
A Company ◽  
Maintenance Plan ◽  
Optimal Type

Keeping the equipment and machinery in working order is a very important activity in the field of industrial production, being specific to the maintenance department within an enterprise. Ensuring an optimal in operation of the manufacturing systems is closely related to the prevention of defects, an action that must be found in a planning and scheduling of preventive-planned maintenance works. In the paper, in addition to the introductory part on the main objectives and implementation of the maintenance system and maintenance-specific operations, a case study is conducted for the planning and organization of maintenance in a company equipped with plastic injection machines. The main stages developed consisted in elaborating the maintenance plan, establishing the optimal moment for replacing the machine tools, choosing the optimal type of machine tool and establishing the elements of random wear of the machine tools. It is concluded that the optimal type of injection molding machine that will be chosen to replace the T10 injection molding machine is T14, because it has a minimum average cost of acquisition, maintenance and repair, respectively 42.286 UV.

Choice and Exchange of Lubricating Oil for Injection Molding Machine

2019 ◽  
Vol 12 (4) ◽  
pp. 378-382
Author(s):  
Shan Syedhidayat ◽  
Quan Wang ◽  
Al-Hadad M.A.A. Mohsen ◽  
Jinrong Wang
Keyword(s):  
Injection Molding ◽  
Dimensional Accuracy ◽  
Low Noise ◽  
Working Environment ◽  
Lubricating Oil ◽  
Lubrication System ◽  
Molding Machine ◽  
Oil And Grease ◽  
Injection Molding Machine ◽  
The Stability

Background: One of the most common manufacturing equipment for polymer product is injection molding machine. In order to ensure the precise, stable and continuous operation of the injection molding machine, the maintenance of the lubrication system must be done well. The stability, reliability, rationality and low noise performance of the lubrication system of injection molding machine directly affect the quality of injection products, dimensional accuracy, molding cycle, working environment and maintenance. Objective: The purpose of this study is to introduce the methods of choice, maintenance of lubricating oil for injection molding machine from many literatures and patents in the recent years, such as lubricating oil device, lubricating composite and structure. Methods: An example of the 260M5 automatic injection molding machine is introduced for the inspection and maintenance of the lubrication system including lubricating oil and lubricating grease. Results: To ensure the lubrication of the injection molding machine, it needs to strictly observe the lubrication time and modulus of the injection molding machine. It needs to strictly control the temperature rise of the lubricating oil and select the correct lubricating oil and grease to ensure the lubrication quality. Conclusion: In the operation of the injection molding machine, it is necessary to check that the lubricating oil is sufficient and the lubricating points are working properly. It ensures sufficient lubrication of the injection molding machine and strictly observes the lubrication time and modulus of the injection molding machine. The stored lubricating oil should be sealed well to prevent air pollution.

Analysis on vibration characteristics of screw in filling process of dynamic injection molding machine

2016 ◽  
Vol 36 (8) ◽  
pp. 861-866 ◽  
Author(s):  
Quan Wang ◽  
Zhenghuan Wu
Keyword(s):  
Injection Molding ◽  
Processing Parameters ◽  
Axial Vibration ◽  
Filling Process ◽  
Molding Machine ◽  
Lumped Mass ◽  
Injection Molding Machine ◽  
Injection Speed ◽  
And Performance ◽  
Injection Screw

Abstract This paper presents a study of the characteristics of axial vibration of a screw in the filling process for a novel dynamic injection molding machine. By simplifying a generalized model of the injection screw, physical and mathematic models are established to describe the dynamic response of the axial vibration of a screw using the method of lumped-mass. The damping coefficient of the screw is calculated in the dynamic filling process. The amplitude-frequency characteristics are analyzed by the simulation and experimental test of polypropylene. The results show that the amplitude of a dynamic injection molding machine is not only is related to structure parameters of the screw and performance of the material, such as non-Newtonian index, but also depends on the processing parameters, such as vibration intensity and injection speed.

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