Plastic Manufacturing Via Injection Moulding and Rejection Handling [PDF]

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Summer Internship Project Report on A Study of Plastic Manufacturing via Injection Moulding & Process of Rejection Handling By SAURABH SHARMA

STEP-049 Under the Supervision of Mrs. Suchita Shukla Assistant professor In Partial Fulfillment of the Requirements for the Degree of Post Graduate Diploma In Management 2016-2018 at

SCIENCE AND TECHNOLOGY ENTREPRENEUR’S PARK HARCOURT BUTLER TECHNOLOGICAL INSTITUTE, NAWABGANJ

KANPUR – 208002 DECLARATION I hereby declare that the summer project on “Plastic manufacturing via injection moulding” is submitted by me under the guidance of Mrs. Suchita Shukla, Assistant Professor, Science and Technology Entrepreneurs Park, Harcourt Butler Technological institute, Nawabganj, Kanpur is partial fulfillment of the requirements for the completion of Second Semester of Post Graduate Diploma in management. The results and learnings of this report are not copied and are true and best of my knowledge.

Place: Kanpur Date:

SAURABH SHARMA

ACKNOWLEDGEMENT A summer project is a golden opportunity for learning and self-development. I consider myself very lucky and honoured to have so many wonderful people lead me through in completion of this project. I express my deepest thanks to K-Three Electronics Pvt. Ltd. for providing me with this wonderful opportunity and giving necessary advices and guidance to make my internship easier and fulfilling. I also am deeply grateful to entire management team of STEP HBTI Kanpur for letting me dirty my hands on a practical aspect of corporate life. I wish to express my indebted gratitude to Mr. Ramphal Singh (Production Head) K-Three Electronics Pvt. Ltd. for providing me with an opportunity to work with their organization. I would like to express a special thanks to Mr. Neeraj Verma who despite being extraordinarily busy with his duties, took time out to hear, guide and keep me on the correct path. His judicious and precious guidance were extremely valuable for my study both theoretically and practically. I express my deepest thanks to Mrs. Suchita Shukla for his guidance and support. She supported me by showing different method of information collection about the company. He helped all time when I needed and gave right direction toward completion of project.

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Saurabh Sharma

PREFACE Injection molding is the most commonly used manufacturing process for the fabrication of plastic parts. A wide variety of products are manufactured using injection molding, which vary greatly in their size, complexity, and application. The injection molding process requires the use of an injection molding machine, raw plastic material, and a mold. The plastic is melted in the injection molding machine and then injected into the mold, where it cools and solidifies into the final part. The steps in this process are described in greater detail in the next section.

This study was conducted to analyze various factors of defects in injection moulding process of the production line of manufacturing organization. Based on some reading material such as, journal, book and some study states that some factors such as machine, man, mould, method, technology and material caused defects in injection moulding process. The objective of this study is to determine the factors that caused defect in injection moulidng process in production line. Interview secession will be conducting with production line and several departments manager to have some discussion and observation about the study. In the nut shell, I wish that this study will be one of the references to be use in future and may be can have some improvement for this study.

I am privileged to be one of the students who got an opportunity to do my training with KThree Electronics. My involvement in the project has been very challenging and has provided me a platform to leverage my potential in the most constructive way. This project however is an attempt to share as best as possible my experience in corporate world with all my

colleagues and my faculty. I would be delighted to receive reader’s comments which maybe valuable lessons for my future projects.

CERTIFICATE

I Mrs. Suchita Shukla hereby certify that Saurabh Sharma student of PGDM at Science Technology Entrepreneurs Park Harcourt Butler Technological Institute, Kanpur, Uttar Pradesh has completed the Project Report on Manufacturing Of Plastic Via Injection Moulding, K-Three Electronics Pvt Ltd, under my guidance.

Mrs. Suchita Shukla Assistant Professor Department of Finance

TABLE OF CONTENTS Abstract Executive Summary Chapter 1 Industry Profile •  Introduction  History  Market size  Industry Insight ● Raw Material Insight ● Application Insight ● Regional Insight ● Competitive Insight  Industry Information  Government Initiatives  Major Company

Chapter 2 Company Profile  Introduction  Vision & Mission  Values  Community Involvement  Testimonials  Carrers  Product Profile  Quality Assurance  Team and management  SWOT Analysis Chapter 3 Study Of Plastic Manufacturing Via Injection Moulding and Rejection Handling       

Introduction Injection Moulding Overview Process Characterstics Process Cycle Machine And Equipment Injection Unit Clamping Unit

    

Machine Specification Moulding Defect Rejection Analysis Costing and Estimation Application

Chapter 4 Research Methodology       

Project Objectives Scope Research Methodology Research Design and Collection Of Data Tools For Analysis Sampling Method Sample Size

Chapter 5 Data Interpretation and Analysis  Data Interpretation  Implementation Of Data  Finding  Conclusion  Recommendation  Limitation Of Study  Questionnaire  Bibliography

ABSTRACT

Injection Moulding (IM) is considered to be one of the most prominent processes for mass production of plastic products. One of the biggest challenges, facing injection molders today, is to determine the proper settings for the IM process variables. Selecting the proper settings for an IM process is crucial because the behavior of the polymeric material during shaping is highly influenced by the process variables. Consequently, the process variables govern the quality of the parts produced. The difficulty of optimizing an IM process is that the performance measures usually show conflicting behavior. Therefore, a compromise must be found between all of the performance measures of interest. This thesis demonstrates a method of achieving six sigma standards in small and medium plastic injection moulding enterprises.

In recent couple of decades, it has been seen that the ratio of the required commodity changes and brings forth the requirement and necessity of quality improvement to be practiced more. Total quality for continuous improvement for reliable products is used by many industries for improvement of service and quality of product. In the previous decade, a novel based philosophy known as “Six Sigma” has been incorporated and very well established in many companies The goal of “Six Sigma” in any regime or technical aspect i.e. designing, manufacturing, processing, marketing or testing , improves effort to obtain a durable or long term defect rate of only 3.4 defective parts per million manufactured

This study mainly focused on six sigma quality philosophy and other related philosophy that is implemented in these studies in order to identify the Current problem or rejection criteria facing by a manufacturing company. The root cause in this study for the black dot defect had been successfully determined. Corrective action to overcome this quality problem has been suggested. The “Six Sigma” Philosophy provides a step-by-step quality improvement Methodology that uses statistical methods to quantify variation

CHAPTER 1 INDUSTRY PROFILE

INTRODUCTION Injection moulding is used to create many things such as wire spools, packaging, bottle caps, automotive parts and components, Gameboys, pocket combs, some musical instruments (and parts of them), one-piece chairs and small tables, storage containers, mechanical parts (including gears), and most other plastic products available today. Injection moulding is the most common modern method of manufacturing plastic parts; it is ideal for producing high volumes of the same object

HISTORY American inventor John Wesley Hyatt together with his brother Isaiah, Hyatt patented the first injection moulding machine in 1872 This machine was relatively simple compared to machines in use today: it worked like a large hypodermic needle, using a plunger to inject plastic through a heated cylinder into a mould. The industry progressed slowly over the years, producing products such as collar stays, buttons, and hair combs. The German chemists Arthur Eichengrün and Theodore Becker invented the first soluble forms of cellulose acetate in 1903, which was much less flammable than cellulose nitrate. It was eventually made available in a powder form from which it was readily injection moulded. Arthur Eichengrün developed the first injection moulding press in 1919. In 1939, Arthur Eichengrün patented the injection moulding of plasticised cellulose acetate.

The industry expanded rapidly in the 1940s because World War II created a huge demand for inexpensive, mass-produced products. In 1946, American inventor James Watson Hendry built the first screw injection machine, which allowed much more precise control over the speed of injection and the quality of articles produced This machine also allowed material to be mixed before injection, so that coloured or recycled plastic could be added to virgin material and mixed thoroughly before being injected. Today screw injection machines account for the vast majority of all injection machines. In the 1970s, Hendry went on to develop the first gas-assisted injection moulding process, which permitted the production of complex, hollow articles that cooled quickly. This greatly improved design flexibility as well as the strength and finish of manufactured parts while reducing production time, cost, weight and waste. The plastic injection moulding industry has evolved over the years from producing combs and buttons to producing a vast array of products for many industries including automotive, medical, aerospace, consumer products, toys, plumbing, packaging, and construction

In 1847 Jöns Jacob Berzelius produced the first condensation polymer, polyester, from glycerin (propanetriol) and tartaric acid. Berzelius is also credited with originating the chemical terms catalysis, polymer, isomer, and allotrope, although his original definitions differ dramatically from modern usage. He coined the term "polymer" in 1833 to describe organic compounds which shared identical empirical formulas but which differed in overall molecular weight, the larger of the compounds being described as "polymers" of the smallest. The first man-made commercial plastic was invented in Britain in 1861 by Alexander Parkes. He publicly demonstrated it at the 1862 International Exhibition in London, calling the material "Parkesine". Derived from cellulose, Parkesine could be heated, molded, then retain its shape when cooled. It was, however, highly flammable, prone to cracking, and very expensive to product. In 1868, American inventor John Wesley Hyatt developed a plastic material he named Celluloid, improving on Parkes' invention so that it could be processed into a finished form. Together with his brother Isaiah, Hyatt patented the first plastic injection molding machine in 1872. This machine was relatively simple compared to machines in use today: it worked like a large hypodermic needle, using a plunger to inject plastic through a heated

cylinder into a mold. The industry progressed slowly over the years, producing small products such as collar stays, buttons, and combs. The industry expanded rapidly in the 1940's because World War II created a huge demand for inexpensive, mass-produced products. In 1946, American inventor James Watson Hendry built the first screw injection machine, which allowed much more control over the speed and quality of the plastics injection. This machine also allowed material to be mixed before injection, so that coloured or recycled plastic could be added to virgin material and mixed thoroughly before being injected. Today screw injection machines account for the vast majority of all injection machines. In the 1970s, Hendry went on to develop the first gas-assisted injection molding process, which permitted the production of complex, hollow articles that cooled quickly. This greatly improved design flexibility as well as the strength and finish of manufactured parts while reducing production time, cost, weight and waste.

1. A Brief Hisory of Injection Molding Plastic injection molding has an interesting story 2. 1. 1861-1868  Alexander Parkes invented the first man-made commercial plastic in 1861.  In 1868, an American inventor named John Wesley Hyatt developed a plastic material called Celluloid made by combining cellulose nitrate and camphor. 3. 2. 1872-1909  John Wesley Hyatt and his brother Isaiah patented the first injection molding machine in 1872. It basically worked like a large hypodermic needle.  In 1909, Leo Hendrik of Belgium discovered phenolformaldehyde plastic and was the first to control it and make it usable on a large scale. 4. 3. 1930-1939  During the 1930s, major vinyl thermoplastics still used today like polystyrene, PVC, and the polyolefins were in the initial development stage.  In 1938, polystyrene (a plastic still used widely today) was officially invented. The following year, WWII brought a huge demand for cheap, mass-produced materials. Polystyrene plastic 5. 4. 1941-1946  Developed by Du Pont as a fiber in the 1930s, nylon was first used as a molding material in 1941.  In 1946, an American inventor named James Watson Hendry built the first extrusion screw injection machine. The rotating screw made the injection speed easier to control and it helped produce higher quality results.

6. 5. 1946-1955  During these particular years, polyethylene, polystyrene, and other materials that had been more expensive in the past, were starting to be produced more cheaply.  They also started to replace not only other plastics, but also more traditional materials like wood, metal, leather, and glass. Made from polyethylene plastic 7. 6. 1956-1965  In 1956, W.H. Willert developed the reciprocating injection molding machine. In this machine, the screw moves backwards and forwards during the mold cycle.  After mixing, the screw stops turning and the whole screw pushes forward, plunging the material into a mold.  This time period also brought forth many useful new thermoplastics like high-density polyethylenes and polypropylene. 8. 7. 1960-1980  In the 1960s, polysulphones, aromatic polyesters, and polyamides were introduced.  In the 1970s, James Watson Hendry went on to build the first gas-assisted injection molding process. This made producing complex, hollow products that cooled quickly possible.  His new design improved the strength and finish of manufactured parts and reduced production time, cost, weight, and waste. 9. 8. Today  Now (in 2015) there are plastic injection molding companies whose sole purpose is to make virtually anything (car parts, tools, toys, décor) by using electric injection molding machines.  Most anything can be made out of plastic these days, and businesses are taking advantage of this by outsourcing their large scale injection molding projects to injection molding companies. 10. Call Streamline Plastics Today  If you own a business and you’ve been looking for a plastic injection molding company to make your 3- dimensional designs a reality, call Streamline Plastics today.  Finding injection molding companies that are as efficient, accurate, and timely as us is difficult. Don’t try to design a product, create a prototype, and use an injection molding machine on your own.  We can do that for you if you contact us today by calling 801-782-3660 or by visiting streamlineplastics.com. Leading home-grown injection moulding machinery makers are increasingly becoming techno-savvy as they aim to raise their capacity to meet the rising demand for made-in-India machines From being a mere mechanical pile of churning out moulded plastic products, the injection moulding machinery industry today has become a major contributor in the process of converting plastics to complex and complicated parts and assemblies. This move up the value

chain has become possible as customers have begun to voice more demands in terms of changes in cost, quality and service. The shift in the Indian injection moulding industry where plastic processors have gone from ‘quality is secondary’ to ‘quality is everything’ has been possible due to social, economic, regulator and technological factors.

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It is important to understand megatrends to match or predict technological trends in any industry. Economic factors such as disposable incomes, imports of products and technological factors like stringent standards, cost reduction and weight reduction requirements are playing an important role in the injection moulding industry. For a country like India, the exposure to the western counterparts have made the customers more demanding

in

terms

of

safer

niche plastics moulded

products.

At this juncture, it would be safe to say that injection moulded products in India have attained the omnipresent status. “Segments that use injection moulding technology include fastmoving

consumer goods

(FMCG), household products,

engineering,

automotive,

electrical/electronic and many other sectors. In fact, it touches nearly all facets of life. For instance, from a toothbrush to a razor to all caps on all bottles and also nearly all housings on electronics, are injection moulded. By and large all these sectors are growing in consumption and the trend is towards better quality and sustainability. Moreover, additional opportunities are abound in multi-colour and multi-component injection moulding. This implies that a lot of opportunities are set to come to the injection moulding machinery sector in the coming years,” says Vagish Dixit, Managing Director, ALPLA India Pvt Ltd, a leading global company in the business of plastic bottles and caps for the FMCG segment. From a rigid packaging perspective, Dixit highlights trend in the arena of bi-injection caps with turn-table, core-back and cube platforms. He believes that Indian machine manufactures can support the first two as of now. But thin walled containers (with and without in-mould decoration) are also an area of opportunity for manufacturers, since currently the machines for this application come

mostly from Europe.

For injection moulding machinery manufacturers, right now is the golden era as optimistic images of growth are being painted by all. “Around 35% of all polymers are converted

using injection moulding. The injection moulding industry is driven by speed, productivity, reliability, energy conservation and automation. The machines are expected to provide faster production with lesser rejections,” opines Shirish V Divgi, Managing Director, Ferromatik Milacron India Ltd, one of the leading manufacturers of plastics injection moulding machines in the country.

Talking Tech Elaborating further on the trends in this industry, Anil George, Co-Founder & Director, AutoDynamic Engineering Pvt Ltd, says, “Injection moulding along with extrusion has now captured the industry because of elimination of a complete step in manufacturing of a plastic part. The process involves an extrusion process which directly feeds the material to the injection moulding machine for manufacturing the part. This is called the injection molding compounder.” George, who in his 23 years of experience has conceived and developed, specialised and customised plastics products for the automotive sector, adds, “Another recent trend involves technologies that optimise material cost. This can be in terms of optimised product design using the latest Computer-Aided Design (CAD) technologies, material advancements like use of light-weighting fillers, processes like foaming, gas, etc to reduce the material consumption.”

MARKET SIZE The market size of injection molding machine was USD 4.28 billion in 2015 and is projected to reach USD 4.86 billion by 2021, registering a CAGR of 2.2% between 2016 and 2021. There is an increasing demand of automobiles in the emerging economies such as China, India, and Japan because injection molding machines are majorly used for manufacturing automotive parts. This is fueling the growth of the injection molding machine market in these regions. Properties such as low energy consumption, low maintenance cost, short production

cycle time, and high accuracy of all-electric injection molding machines contribute to the growth of the injection molding machine market.

Injection molding machine for plastic products to account for the major share of the market till 2021 The injection molding machine market is segmented by product type, namely, plastic, rubber, metal ceramic, and others (includes micro-injection molding, gas injection molding, and liquid silicone rubber injection molding). Plastic is the most preferred product type of injection molding machine and accounts for a major share in the global injection molding machine market. The dominance of the plastic segment is expected to continue between 2016 and 2021 due to its increasing demand from the end-use industries such as automotive, consumer goods, and packaging.

Automotive industry to be the largest industry for the injection molding machine market between 2016 and 2021 The automotive industry accounted for the largest share in the injection molding machine market. This is due to the growing automotive industry and improving standard of living in the developing nations. Moreover, the increasing number of passengers and commercial vehicles in the region is fueling the growth of the market. Injection molding machines are predominantly used in manufacturing automotive components, interior wrapping, and numerous assembly parts.

Asia-Pacific to be the largest market during the forecast period The injection molding machine market is broadly segmented into five regions, namely, AsiaPacific, North America, Europe, the Middle East & Africa, and Latin America. Asia-Pacific is

the largest market, followed by Europe, and projected to be the fastest-growing market during the forecast period. Growing industrialization and increasing number of passenger and commercial vehicles have offered enormous opportunities for various automotive industries to use injection molding machines in the Asia-Pacific region. Currently, the global injection molding machine market is dominated by various market players, such as Haitian International Holdings Limited (China), Chen Hsong Holdings Limited (China), Sumitomo Heavy Industries (Japan), Milacron Holdings Corp. (U.S.), Engel Austria GmbH (Austria), Nissei Plastic Industrial Co., Ltd, (Japan), Arburg GmbH & Co. KG (Germany), Husky Injection Molding Systems Ltd. (Canada), Dongshin Hydraulic Co., Ltd. (Korea), The Japan Steel Works Ltd. (Japan), KraussMaffei Group GmbH (Germany), Negri Bossi S.P.A. (Italy), and others.

Study Coverage: The research study aims at identifying emerging trends and opportunities in the global injection molding machine market along with a detailed classification of the market, in terms of value and volume. It identifies the key players in the global market and provides a comprehensive competitive landscape. The research study also includes a detailed segmentation of the global injection molding machine market on the basis of end-use industry, type, and region.

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Industry Insights The global injection molded plastic market size was valued at USD 199.86 billion 2014. The industry is anticipated to witness significant growth in near future on account of increasing plastics component demand across various end-use industries including packaging, automotive, electrical & electronics, home appliances, and medical devices. Injection molding process involves manufacturing of molded products by injecting molten plastic materials using heat into a mold and then solidifying them. Recent innovations to minimize the rate of faulty production have enhanced the significance of injection molded technology in the mass production of complicated plastic shapes. Increasing construction spending, particularly in emerging markets of Brazil, China, India, Mexico, Russia, and South Africa is expected to drive demand. This is further supported by versatile properties of finished products including better heat and pressure resistance, making them more applicable to various industries. Low crude oil prices coupled with China’s economic situation have had a significant impact on petrochemicals industry. China plays an important role in the bulk production and trading of petrochemical derivatives. Various companies have adopted strategies to sustain annual growth and minimize the impact of lowered oil prices on profit margins. Volatile prices of major raw materials including benzene, ethylene, propylene and styrene coupled with growing environmental concerns regarding their disposal is expected to hinder

market growth over the forecast period. To overcome such challenges, the industry has shifted its focus towards developing injection molded plastics using bio-based counterparts. Major plastic manufacturers have been forming joint ventures and have been collaborating with biotechnology companies to synergize their functions to manufacture bio-based plastics and finished products.

Raw Material Insights Polypropylene emerged as the largest raw material segment and accounted for over 35% of total demand in 2014. High demand for injection molded polypropylene in household goods, automotive components, and packaging applications is a major factor driving its consumption. Increasing polypropylene finished products penetration in food packaging, protective caps in electrical contacts and battery housings is expected to further drive its demand over the forecast period. Polypropylene components are being widely used in food packaging and electrical contacts on account of corrosion resistance and electrical insulation properties respectively. On account of aforementioned, the segment is expected to witness the highest growth over the forecast period. ABS emerged as the second major raw material for injection molded plastics and accounted for over 25% of the total revenue in 2014. High ABS component demand in medical devices, automotive components, electronic housings and consumer appliances manufacturing is expected to drive its growth over the forecast period.

Application Insights Packaging was the leading injection molded plastics application segment with a net demand of over 30,000 kilo tons in 2014. The finished products used in packaging undergo various development phases to cope up with regulatory guidelines and end-user requirements.

Increased shelf life of foodstuffs, better performance towards wear & tear, durability are a few requirements that plastics need to meet for packaging applications. Injection molded plastics hold immense potential particularly in the medical and automotive industry. The industry is expected to witness the highest growth in the medical devices & components sector. Biocompatibility, optical clarity, and cost efficient method of production is projected to drive demand in the medical industry. The segment is anticipated to grow at a CAGR exceeding in terms of value to reach a net worth of USD 24.59 billion by 2022. Stringent regulatory scenario regarding medical grade polymer use in healthcare sectors is anticipated to positively impact growth in the industry over the forecast period. Growing preference towards bio-degradable polymers among medical device manufacturers is also expected to create lucrative opportunities in medical industry over the forecast period. A strong shift in trend towards replacing steel with plastics in automotive industry is expected to spur market growth over the forecast period. Government regulations in the recent past have forced automotive manufacturers to use plastics instead of other materials such as iron and steel. Automobile manufacturers have been focusing on reducing the overall weight of the vehicle to improve fuel efficiency. Increasing use of plastics to replace metals & alloys in automotive components is expected to drive product demand in automobile end-use segment, thereby providing immense opportunity to injection molded plastics to penetrate the industry  

Regional Insights Asia Pacific injection molded plastic market dominated the global demand and accounted for over 35% of total volume in 2014. Increasing infrastructure spending coupled with growing automobile demand in countries such as China, India, Indonesia, and Malaysia are expected to drive market penetration in the region. Major end-use industries such as electronics and automobile are shifting their manufacturing base Asia Pacific countries such as China, India, Thailand and Indonesia owing to low labor costs. Government incentives in the firm of tax benefits are offered to manufacturers in these regions. This factor increases the requirement for manufacturing various automotive and

electrical parts which in turn is expected to increase injection molded plastics demand over the forecast period. Europe was another major injection molded plastic market with a total demand estimated to reach USD 75.10 billion by 2022. Europe’s Non-food & beverages packaging applications include cosmetics & toiletries, pharmaceutical and household chemicals. Increasing electronic appliances demand such as laptops and cellular phones particularly in UK, Germany and France is expected to drive their demand for consumables & electronics application. Europe’s automobile industry growth is projected to drive this region’s demand over the forecast period. A majority of future demand is expected to come from economies including China, India, Brazil, Germany, Thailand, and the U.S.

Competitive Insights The global injection molded plastic market is highly fragmented with the presence of large unorganized sector particularly in the Asia Pacific and Latin America. Companies, particularly hailing from Asia Pacific have constantly been looking for significant capacity additions over past few years to take advantage of operational excellence and achieve economies of scale. Diverse product portfolio and differentiation make the market competitive regarding price and distribution channels. Major companies operating in the global injection molded plastics industry including BASF, Dow Chemical Company, DuPont and HTI Plastics have integrated their operations across the value chain to enhance their market presence. Other players having a significant stake in the industry include SABIC, LyondellBasell, Eastman Chemical Company, Huntsman, Ineos Group and Magna International Inc.

Global injection molded plastics market is estimated to reach $162.1 billion by 2020, growing at a CAGR of 4.9% during 2015-2020. Injection molding is a manufacturing process for producing plastic products by injecting molten material into a mold where it is melted, cooled and subsequently solidified as the final part or product. Both thermoplastic and

thermosetting injection molded plastics are used for manufacturing of various parts and components across industries. The major thermoplastic polymers used in injection molding are polypropylene, low-density polyethylene, high-density polyethylene, polycarbonate, polystyrene, polyvinyl chloride, polyurethane, polysulfone etc. Epoxy resin, polyester and melamine formaldehyde are some of the thermosetting polymers used for injection molding purpose.

Injection molded plastics are used in production of complex and intricate shaped parts for precision with least waste. Owing to these advantages, injection molded plastic are used in automotive components, interior wrapping, and miscellaneous assembly parts manufacturing process. It is also used in packaging applications to produce packaging parts & components to increase the aesthetics and consumer friendliness of the packaging products. Injection molded plastics are widely preferred in building and construction purposes owing to the strength, durability, and appearance of the injection molded plastic parts. In building and construction, these plastic parts or components are majorly employed for piping systems, insulation, wall board, and roofing purposes. Healthcare industry is the fastest growing application segment for injection molded plastic industry during the forecast period. Blood sample analysis cuvettes, pregnancy test devices, housings for needles, parts of medical devices are few of the preferred segments, owing to the lightweight, cost-effectiveness and easy serializable properties of injection molded plastic. Injection molded plastics are used with automated process thereby reducing manufacturing cost. It also reduces the waste production in production process. Low production waste and faster production process would augment the growth of injection molded plastics market. Along with this, the process has ability to use different types of plastics simultaneously to manufacture plastic parts. Furthermore, technological advancement in injection molding process where robots are used to perform different operations such as finishing and assembling injection molded parts and loading components into the injection molding would foster the growth of the market. However, high initial tooling cost and volatile petroleum prices may hamper the growth of the market.

Segment Review

World injection molded plastics market is segmented based on the types of raw materials, end-user industry and geography. On the basis of raw materials, world injection molded plastics market is segmented into polypropylene, high density polyethylene (HDPE), polystyrene and acrylonitrile butadiene styrene including others. Amongst them, polypropylene is the leading raw material used in injection molded plastic owing to its easy to mold nature, electrical insulating properties, heat resistance and low cost. In 2014, Polypropylene accounted for around 39% of the world injection molded plastics market. Further, on the basis of end-user, the market is segmented into packaging, automotive, consumer goods & electronics, building & construction and medical disposal. Packaging is the leading application segment for injection molding which accounts for around 37% of the world demand in 2014. Rigid packaging used in industrial and consumer packaging industry are estimated to fuel demand for injection molded plastics in packaging industry. Geographically, world injection molded plastics market is segmented into North America, Europe, Asia-Pacific, and LAMEA. North America is the leading market for injection molded plastics which accounted for around 35.0% of the total market share in 2014. Asia-Pacific and LAMEA exhibited a large scale demand for injection molded plastic due to the growing application in building & construction, consumer appliances, and automotive industries. AsiaPacific is expected to grow at CAGR of 5.7% during 2015-2020.

India Review It was with polystyrene that the Indian plastics industry made a favorable beginning in the year 1957. Among the developing countries, India maintains its major stand as one of the most promising exporters of plastics. The plastic industry has excellent potential in terms of infrastructure, availability of cheap labor and capacity. Hence, this industry is supported by a large number of polymer producers and manufacturers of plastic process machinery and mold manufacturers. Besides this, increasing use of plastic parts, owing to increasing industrialization is expected to boost the Indian injection molded plastics market.

Industry Information Injection Molded Plastic is resin that has been heated until molten and then forced into a premade mold or cavity in the shape of the intended plastic product or object. When the melted

plastic has cooled and hardened, the mold is removed to reveal a hard, plastic part in the shape of the mold cavity. Products made from plastic injection molding, or custom injection molding, include a wide range of everyday household items such as mop buckets, plastic containers, screw driver handles and even video game cartridges. Injection molding can use a wide variety of starting materials, including most polymers. Plastic injection molding gives the injection moulders the freedom to choose exactly what the best material for the final molded plastic part would be and requires a lot of calculation as to composition of the resin as well as temperature and pressure in the mold. All these variables can affect the final quality of the plastic. Injection molding uses thermoplastics, called thermoplastics injection molding, thermoset materials or elastomers, depending upon the intended use of the final product. Thermoplastics and thermosets harden completely after cooling in the plastic injection mould; elastomers however, retain a sense of elasticity and so are used to produce items such as rubber bouncing balls. Other variations of plastic molding, or insert molding, include gas assist injection molding which uses an inert gas, such as nitrogen, to create a hollow portion in the mold, and to force the molten plastic into the mold cavities. Another is reaction injection molding; reaction injection molding machines require one further step which is the addition of a curing agent in the mold. This is required for the specific product material to maintain shape and strength once removed from the mold.

The basic machinery used in the process of injection molding consists of a hopper - where the plastic pellets are placed prior to being heated. The plastic material is then fed into a heating unit where it is heated and mixed until molten, at which point dyes or other chemical agents can be added to change the final appearance and feel of the product. Next, an injector, or screw, forces the molten plastic into the mold cavity under hydraulic or mechanical pressure, to ensure that there are no air pockets. Most molds will allow air bubbles to escape to avoid damaging the final product. Cooling liquids are sometimes used around the mold chamber of the machine to extract heat from the plastic and speed up the cooling process, thus saving time in overall manufacturing. The two halves of the plastic injection mold are then pulled apart to release the plastic part. Ejecting pins or rods may have to be used to remove the plastic part from the mold. The entire process can take a matter of seconds or as many as a few minutes to get one complete plastic part. Injection molders are not limited by

manufacturing capabilities when it comes to material choice, and are able to fabricate a wide range of product shapes and sizes. If a mold can be made for an object, plastic molding can be used to produce a product. Everything from car bumpers to intricate medical equipment can be made using the techniques of melting the appropriate material, forcing it into a premade cavity and allowing it to cool. Compared to other forms of plastic parts production, injection molding is a cost effective manufacturing method. It can be used for high production runs, and in fact the more parts that are made from a mold, the more cost-effective it is. Once a mold has been made for a certain product, it can be used again and again to produce the same object with close tolerances. In injection molding, there is little or no change in the manufacturing process between cycles, and so often the plastic part extricated from the mold will need little finishing. Furthermore, because the molten plastic is forced only into the space of the cavity, there is very little material waste apart from joining lines and negligible other amounts. The production of minimal scrap saves further money and is a responsible manufacturing practice. Furthermore, what plastic is wasted and considered scrap can often be melted and recycled. Labor costs for the injection molding process are minimal as there is little need for human interference in the injection process. There are important considerations to be made when discussing plastic injection molding however. Firstly, all the plastic material that is forced into the mold needs to be removed at some point, therefore mold design needs to be carefully considered. A complex rigid, square design might result in cracks or stress marks on the final product when trying to extricate it from the cavity. There also needs to be rods or pins in place to help remove the plastic part from the mold. Plastic injection molds are costly and so it is imperative to ensure that the plastic part can be removed from it once cooled. Another consideration concerning removal is the existence of joining lines, or imperfections in the final products that may require finishing services before being used. The finishing required will usually be minimal, but it is dependant on the quality of the starting material and mold. Finally, while injection molding plastic is a cost effective method of producing plastic goods, custom injection molding will be more costly due to the necessary production of a specific plastic injection mold for the custom product. If however, the quantity of product manufacturing is high, the cost of the plastic injection mold will balance out over time. With so much variance in injection molded

plastics, it is helpful to consider the industries which make use of it such as automotive, medical, consumer and household goods.

Injection Moulded Products

Injection Molded Plastics - Britech Injection Molded Plastics

Injection Molded Plastics - GSH Industries, Inc.

Injection Molded Plastics – ICOMold

Injection Molded Plastics - Penguin, LLC

Injection Moulded Refrigerator Part

Injection Molded Plastic Types 

Custom injection molding is an injection molding process in which the mold is not pre-made, but is formed specifically for the consumer's application.



Double-shot molding is a two-step process in which either the color or the material is injected first. Upon the hardening of the material, a second color or material is



injected into or around the first shape.



Gas-assist injection molding is a process in which inert gas, such as nitrogen, is forced into the melt while it is entering the mold, packing the plastic into the cavities. Gas-assisted injection molding reduces cycle time, part weight, warpage and stress to the cooled parts, as well as minimizing other problems.



Injection blow molding is the process in which plastic is injected into a mold to form a plastic tube. The tube is then blown into a cavity mold to form a hollow part.



Injection molding is a process by which plastics parts and products are formed.



Injection moulders are the tools and die machines used to mold molten plastic.



Insert molding is an injection molding process in which plastic gets injected into a cavity surrounding an insert piece just prior to molding. Plastic insert molding results in a single piece encapsulated by the plastic.



Molded plastic pieces are parts that are formed by pouring heated plastic into molds.



Plastic injection molding is a process by which plastic is heated into a malleable form and pressed into molds.



Plastic injection mold processes are used to fabricate parts with a range of complexities, from simple shapes to precision parts of geometric complexity



Plastic manufacturers fabricate plastic products by injecting molten plastic into molds or dies.



Plastic molding is one of the most common methods of part manufacturing.



Push-pull molding is a process that involves multiple layers with different orientations, providing more uniform properties to the parts than if they were molded from a single direction



Rapid injection molding is primarily used in prototyping and the low-volume production of plastic parts since the production time is drastically shorter than conventional molding process.



Reaction injection molding is an economical option commonly used for larger, more complex polyurethane plastic and rigid foam parts produced in small quantity.



Thermoplastics injection molding is the most common method used to process thermoplastics, due to its ability to fabricate parts with a range of design variances, from simple shapes to high precision parts of geometric complexity.

Injection Molded Plastic Terms Backing Plate - A plate that provides support for the mold cavity block, guide pins, bushings and so forth. Cavity - The space inside a mold into which the materialis

injected.

Charge – The amount of material needed to fill a mold during a single cycle. Cooling Channels - Channel through which a cooling medium flows to control the temperature of the surface of the mold. Cooling channels are located within the body of the mold. High Density Polyethylene (HDPE) - Plastic used to package products with short shelf lives, such as bottles for milk, juice, water and laundry products. Unpigmented HDPE bottles are translucent and have good stiffness. Hydraulic Units - Devices that use the force of fluids to move the mold in the injection molding process. Linear Low Density Polyethylene (LLDPE) - A plastic that is used predominantly in film applications due to its toughness and flexibility. LLDPE is the preferred resin for injection molding because of its superior toughness and is used in items such as grocery bags, garbage bags and landfill liners. Mold - A series of steel plates, which contain cavities into which plastic resin is injected to form a parts Monomer - A relatively simple compound that can react to form a polymer. Melt Index - A test that measures the ability of molten plastic to flow.

Melting Point (Tm) - The temperature at which crystalline portions of polymers melt. A material becomes soft and completely amorphous once it reaches the Tm. Melt Viscosity - A term that refers to the measure of resistance to flow. For all materials, the viscosity decrease as the temperature increases. Polymer - A term that means many units. These units are linked together to form chain-like structures that give polymers unique properties. Polypropylene (PP) - A very strong substance that has the lowest density of the plastics used in packaging. PP has a high melting point, making it ideal for hot-fill liquids. Polystyrene (PS) - A very versatile plastic that can be rigid or foamed and has a relatively low melting point.General purpose polystyrene is clear,hard and brittle . Resin - Any of a class of solid or semi-solid organic products of natural or synthetic origin, generally of high molecular weight with no definite melting point. Most resins are polymers. Thermoplastics - Materials that can be melted by heating and then re-solidified by cooling. Blends of thermoplascs can be prepared by melt-mixing. Thermosets - Materials that "cure" to form solids when heated. Unlike thermoplastics, solid thermosets do not melt when heated, so they are very useful for high heat applications. Toggle Unit - Device that uses mechanical links to move the mold during the formation of injection molded plastics.

Raw material consumption The plastics industry in Pakistan has taken great strides in quest for its success. Today plastics material constitutes as the fourth largest item of imports and this sector alone contributes significantly to the national exchequer in different heads. The industry is growing at an annual average of 15% and in the process of development it has surpassed all other industrial sectors. The per capita consumption in the country has also shown an upward trend during the last 15 years [except post 9/11 events and standoff with India]. Today the domestic consumption of plastics stands at 2.7 kgs, far less than the international

average, yet Pakistan is the second largest domestic market in South East Asia after India. With the 175 million strong population of Pakistan growing at an annual rate of 2.2%, coupled with new foreign and local investment and the government policy advocating use of PP woven bags for industrial packaging, it is expected that the per capita consumption of plastics is like to increase to 4.0 kgs by 2007. Till the early years of 1990s, the customs duty on plastics raw material was on unrealistically higher side of about 110 % which has been gradually brought down to the current level of 20%.

There is a tremendous scope for expansion in the plastics sector. As mentioned above the per capita consumption of plastics as compared with the neighboring and other regional countries, is still low, but again this low consumption level indicates that there is a lot of potential for this industry. For instance, the usage of plastics in auto industry has reversed the consumption trend. With due attention to enhance the productivity and improving quality through innovative technique, the exports of plastics auto parts, which was virtually unheard of in recent years, has become an export industry in Pakistan. Undeniably, had it not been for the import of second hand machinery and cheap labour, the plastics industry in Pakistan would have long vanished. Ironically, the second biggest factor that hampered the development of local plastics industry was a ban on import of brand new plastic machines. The government imposed the ban on plastics machinery for the reason that all of the raw material used for manufacturing of plastics goods was

imported and the machinery may be misused. After long year, the plastics manufacturers succeeded in convincing the government that the plastics machines can manufacture plastics goods and nothing else, and hence the possibility of their being misused for purpose other than the plastics manufacturing is minimal. Other reason for the slow growth of this industry was the NRI (Non Refundable Item) policy (imposed by the government) on plastics machinery, at a time when no injection molding plastics machine was being produce domestically. The ban on new plastics machines was lifted in 1984, but very few new machines of modern technology made their way into Pakistan by way of imports during the next 10 years. However, since then, the industry has taken giant steps in bringing the quality of local products at par with the international standards.

Presently there are 6000 plastics processors in Pakistan. The entire industry is self-financed and SME. The industry contributes around Rupees 8 billion annually to the national exchequer by way of custom duty, sales tax and income tax. Major concentration of plastics processors whether they are injection, blow, extrusion, woven or tubular films manufacturers, is in and around the industrial hubs of Karachi, Lahore, Gujranwala, Peshawar, Faisalabad, Hyderabad , Rawalpindi, Gadoon and Hattar.

The industry can be divided into two sector i.e organized and unorganized. Organized sector, with about 600-700 units, is capable of producing quality products. The unorganized sector produces low quality and cheap products. Despite this, the unorganized sector has grown faster than the organized sector in the past15 years.

Currently there are four plants in Pakistan producing international quality plastics raw material. Surplus production of these plants in being exported. All of them are located within the limits of Karachi. Concept of international plastics exhibitions in Pakistan is relatively new. The first plastics exhibition was held last year May. With more exhibitors coming to Pakistan in a second

plastics exhibition within a year, the plastics industry in Pakistan surely has a lot to show and gain from the international plastics players.

Vital Signs Major Raw Material Producers (operating) Processing Units Employment Direct / Indirect Investments (domestic) Investment (foreign) Capacity Utilization Raw Material Produced (approx) Raw Material Consumed Export value (approx) Export Growth Revenue to Government (approx) Contribution to Total Exports

4 6,000 470,000 Rs. 23.671 Bn 49% 95.4% 253,000 (metric tons) 450,000 (metric tons) Rs.56,369,000 35% average Rs.800 crores (Rs.8 bln) 0.277%

Demand Estimates For Machinery Injection Molding Blow Molding Extrusion

250-500 350-500 1000

Demystifying Energy Saving Devices on Injection Molding Machines Injection molding machine makers at the upcoming Kunststoff Show in Dusseldorf, Germany, in October are touting energy efficient presses that will save 30%, 50%, even 70% of energy use. But is anything really new? Energy efficient all-electric and hybrid injection molding machines have been available for nearly 30 years, and energy saving devices like servo pumps and barrel insulation have been retrofitted onto injection molding machines for almost as long. A cynical explanation for the K Show fuss is that after years of slower business conditions, processors are newly aware of the importance of energy saving. There is also a perceived opportunity for all-electric presses in Europe, where all-electric still accounts for only 15%-

20% of injection molding machine sales (see chart), while hydraulic and hybrid account for 80%-85%,

based

on

a

2011

study

for

Euromap,

Frankfurt-Main,

Germany

(www.euromap.org). In Japan roughly 80% of injection molding machine sales are allelectric vs. 20% hydraulic or hybrid, and in the U.S. sales are roughly 50/50, industry sources say.

Roughly 15%-20% of injection molding machine sales in Europe are all-electric vs. 80%85% hydraulic or hybrid, according to data from Euromap, the European machinery association. All electric presses in the total European machine population are still only 4.5%. Source: Euromap How do original equipment manufacturers (OEMs) calculate their energy savings percentages? Typically by comparing energy use for a new efficient machine function with old-fashioned hydraulics for the same function. An injection molding machine has seven main functions that use energy – plastification, barrel heating, platen movement, injection, clamping pressure, ejection, and barrel retraction. All seven can be made more energy efficient than conventional old-fashioned hydraulics, where a standard induction electric motor runs at constant RPM powering 1-2 hydraulic pumps, which runs even when idling.

Energy efficiency, however, isn’t just a machine function. Efficiency, which is typically measured in kilowatt-hours per kilogram (kWh/kg), is different for each molded part and depends on part weight, cycle time, machine size, and machine efficiency. The SKZ Plastic Institute in Wurzburg, Germany (www.skz.de), which researches energy saving potentials for OEMs and performs energy audits, published a study in 2011 that gives a rough idea of how much energy each machine function uses (see pie chart).

Energy consumption on an electric 100-ton injection molding machine with hydraulic injection makes 83-gram ABS storage trays with 2-mm thick walls in 16.9 second cycles and specific energy use of 0.384 kWh/kg. Source: SKZ

The SKZ tested a 100-ton mostly electric press with hydraulic injection, molding an 83-gram ABS storage tray in 16.9 second cycles and found that plastification consumed by far the most energy at 48%. Next came barrel heating at 17%, followed by clamp force at 12%, and injection force at 11%. Linear movements to open and close molds and retract the barrel for cooling used only minor amounts of energy – 4% each. So plastification and barrel heating are the big opportunities to save energy.

MAJOR COMPANY IN THE IDUSTRY 1. GSH Industries, Inc.

GSH Industries has been manufacturing plastic products since 1986 and we are continuously developing the best solutions in our industry. We are committed to developing high quality custom plastics. GSH Industries has several different divisions including: plastic extrusions, aluminum extrusions, injection molding, rotomolding and rubber extrusions. Our company is recognized for our ability to adhere to customer requests and GSH Industries works hard to separate ourselves as a distinguished supplier of extruded plastics. Located in a 45,000 sq. ft. facility in Strongsville, Ohio, we will quickly deliver all of your plastic solutions. Our company offers solutions for a wide range of markets including: aerospace, appliance, agricultural, drainage, recreational vehicles, OEM automotive, construction, windows & doors, geothermal, solar, packaging, medical, point of purchase, durable goods, signage and much more. Our long lasting products can be customized with a number of attributes to match customers' exact specifications. Our engineers at GSH Industries can design our solutions from a variety of hollow, solid and dual durometer profiles. We are dedicated to

customer satisfaction which is why we will assist customers with designing a profile that is most beneficial for their applications and our engineers can formulate sophisticated profiles for even the most demanding projects.

2. ICOMold

ICOMold is a world-wide leading plastic injection molding manufacturer. We produce lowvolume custom injection molding and plastic parts for our customers worldwide at the highest quality. Our two facilities located in Ohio and China give us the capability to provide a full range of services to our customers.

3. MSI Mold

MSI Mold offers custom injection molding and machining services. We specialize in small to medium sized plastic and machined parts. We`re located in Shelby Township, Michigan and we back up the quality of your products with 30 years of injection molding and tooling experience. We pride ourselves in offering the highest quality made in the USA injection molded parts at your specifications without drama or delay.

4. Britech Injection Molded Plastics

Here at Britech Injection Molded Plastics, we have provided our customers with custom injection molded plastics since 1984. We started as a small company in Florida, but today, we are much larger and offer our products to companies around the world. We can supply our products to you at affordable prices in record time. We use rapid injection molding to help you succeed. Our company has a reputation for putting the customer first. We even use the latest state-of-the-art technology to ensure we always offer the best. Contact us today to find out how we can help you!

5. K- Three Electronics Private Limited K- Three Electronics Private Limited? was established in the year 1970. We provide the best quality of our products. We have made a continuous improvement in the manufacturing of various genuine and trusted quality goods to meet the ever increasing market requirements.

CHAPTER 2 Company profile

INTRODUCTION K Three Electronics Private Limited is a Private incorporated on 30 March 1999. It is classified as Non-govt company and is registered at Registrar of Companies, Delhi. Its authorized share capital is Rs. 30,000,000 and its paid up capital is Rs. 29,750,000.It is inolved in Manufacture of electronic valves and tubes and othe relectronic components. K Three Electronics Private Limited's Annual General Meeting (AGM) was last held on 30 September 2016 and as per records from Ministry of Corporate Affairs (MCA), its balance sheet was last filed on 31March 2016. Directors of K Three Electronics Private Limited are Kanish Khanna, Kapil Khanna and Priyanka sharma. K Three Electronics Private Limited's Corporate Identification Number is (CIN) U32107DL1999PTC099043 and its registration number is 99043.Its Email address is [email protected] and its registered address is B-78, OKHLA INDUSTRIAL AREA PHASE-2 NEW DELHI DL110020 IN

,

-

,

.

Current status of K Three Electronics Private Limited is - Active. *Industry classification is derived from National Industrial Classification. If the company has changed line of business without intimating the Registrar or is a diversified business,

classification may be different. We make no warranties about accuracy of industrial classification.

Vision Through the extensive achievements of our highly-committed team, we strive to remain the premier choice for rapid plastics solutions. We will continue to work towards making a difference in the lives and future of our employees and our communities while advancing the success of our customers.

Mission Our mission is to exceed the expectations of our customers by delivering fast, reliable and superior solutions that are unsurpassed by our competition.

Values K-THREE ELECTRONICS recognizes the importance of the putting the following values into practice. These principles guide our decisions, our actions and ultimately lead to our success: We ensure a safe work environment. We maintain a physically safe facility, and provide a workplace where employees can freely express their professional opinions, beliefs and ideas. We uphold a culture of respect and dignity. We take pride in the contributions and diversity of ideas of our team members, and endeavor to understand each other by putting ourselves “in one another’s shoes.” We inspire empowerment. We encourage problem-solving, communication and employee involvement at every level of the company. We strive to continually learn, adapt and move forward.

We act in stewardship. Employees carefully manage company resources as if they were their own, and respect our customers’ time, financial investments, and the work they entrust to us. We appreciate the importance of a work-life balance, and we recognize that the best balance between work, family, self, friends, and community is different for each individual. We know that a positive work-life balance drives each individual in attaining achievement and enjoyment in their daily pursuits.

Community Involvement K-Three Electronics has been a member of the Lakewood, Townsend, Mountain Chamber of Commerce since 1988 and a member of the Wausau/Marathon County Chamber of Commerce since 1995. In addition, K-Three Electronics’ employees have donated their time and service to area organizations that rely on community contributions. Beneficiaries of their generosity include the Townsend Fire Department, Lakewood Fire Department, Mountain Fire Department, Riverview Fire Department, Doty Fire Department, Community Ambulance and Mountain Ambulance Services, the Wabeno and Lakewood Lions Clubs, as well as the Wabeno, Suring and White Lake school systems. K-Three Electronics frequently donates and sponsors several community events throughout the year. We are a supporter of Scouting, local religious organizations and a major sponsor in a local golf tournament that benefits the Nicolet Medical/Dental Clinic. K-Three Electronics hosts an Annual Walk/Run Challenge for Life that is co-sponsored by the Lakewood Area Chamber of Commerce. The scenic route wraps around the 4.37-mile perimeter of Maiden Lake. Proceeds from the event will go to area Fire/Ambulance Services and the K-Three Electronics Search & Rescue Team who protect and serve the people of the Lakewood, Townsend, and Mountain areas.

Testimonials At K-Three Electronics, we manufacture TIME! In fact, everything we do is about time! We deliver Total Product Solutions for many of the nation’s largest and most successful companies. If someone gave you a week of Time, what would you do with it? That’s just what we’ve done for a majority of our customers, and we are on track to do it again! We’ve accomplished this with our commitment to being Fast, Fluid and Flexible with our implementation of Quick Response Manufacturing (QRM). If you need an injection molder who values your time, then Nicolet Plastics should be your first choice.

Careers K-Three Electronics is seeking hardworking individuals who possess the right combination of interpersonal skill and technical ability to join our innovative team. A career at K-Three Electronics offers: 

Employee empowerment/engagement

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Career path planning

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A drive for personal and professional destiny

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Experience in cross functional teams

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Skill identification and cross training

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Opportunity to build multiple skills that impact critical production operations

Our generous benefit program includes medical, dental, life insurance, STD, LTD, AD&D, FSA (flexible spending accounts), and a 401(k). In addition, we offer paid time off, flex-time and paid holidays. Qualified employees can also benefit from our tuition reimbursement program.

Domain Expertise Leveraging upon our technological expertise and streamlined facilities, we have been able to meet with all the demands of the clients. Our sophisticated facilities have enabled us keeping pace with the ever-changing demands of the market. With our consistent service & on-time delivery, we strive to maintain our goodwill that we have achieved so far. With more than fifteen years of experience in the industry, we carved a niche for ourselves. Today, we are more focused on: 

Client satisfaction



Following ethical business standards

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Technological up gradation of our processes



Healthy Competitiveness

Product Profile We are a leading name in manufacturing a diverse range of plastic molded components and plastic molded automotive parts. Our vast range includes plastic molded Refrigerator parts, washing machine parts, television parts, Ac parts. These products are at par with durability, reliability, highly rated functionality, accuracy, flawless design and other user-friendly

features.

All the products are manufactured using premium quality raw materials, which are sourced from most trusted suppliers. Some of our suppliers are: 

Bayer India Limited



GE Industrial (India) Limited



Du Pont (India) Limited



Indian Petrochemical Corp. Limited

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SRF Polymers Limited

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DSM EP (India Pvt. Limited)

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Korea Engg. Plastic Company Limited

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Laxness ABS Limited



Aalekh Polymers Pvt. Limited



LG company limited



Reliance industry

In the course of production, we consistently receive guidance and directions from Mr. Rajiv Ratra. His vision coupled with technological enhancements and dedicated workforce has enabled us to keep ourselves at par with the industry demands. Optimizing on all our advanced production unit, we assure that every product that rolls out of our manufacturing unit has attributes of modern technology, simplicity and in-built toughness. Adding to our expertise, we have our own sister concern 'Consult Techniques' which holds respectable product volumes (WHAT KIND OF PRODUCT) and serve in the best manner to its clients.

Facilities We Possess We boast of a modern infrastructure, which is well equipped with sophisticated machines, so we continuously upgrade our machines to maintain their efficiency. Following are some of the facilities we have: 

Machine Shop: Our machine shop is equipped with a battery of injection molding machines and other modern machines. These machines are continually updated to the best technology to maintain their efficiency.



Tool Room: The tool room is used to make molds, which offers higher level of accuracy to our components. Our tool room has modern machines and vertical machining centers.



Design: Lot of attention is given to the design of our products, as we understand the level of performance depends largely on the design of the products. For better

product development, we pursue extensive research and use the most advanced machines for our designing requirements. We are well equipped with softwares like Autocard, Unigraphic etc.

Quality Assurance Quality Policy: "To achieve customer delight by manufacturing products as per customer specification and on - time delivery of good quality products at competitive price through continuous improvement at all levels” At our unit, we have a separate division for quality inspection wherein we have all the facilities, which are required for successful quality assessment. All the products like plastic moulded components and plastic moulded electrical parts that we manufacture undergo stringent test and checks in order determine their quality. While testing, various parameters like design, size, performance and others are taken into consideration. Each test takes place under the strict vigilance of our supervisors and quality checking inspectors. All the tests are conducted using advanced testing equipment and modern testing measures that help in testing the products. We assure every component is thoroughly inspected in order to make us achieve our goal of total product management (TPM).

Our Strengths 

Goodwill in the international market

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Cost effective

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On-time delivery

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Safe packing



Customized solutions

Team And Management Supported by a team of expert personnel and their quality awareness, we are able to meet with all the specific demands of the client. Toiling hard in our unit, our team members are focused regarding their job and have made breakthroughs in efficient product design and development. Our pool of engineers and technocrats work in close co-ordination with our clients & offer products that meet the specific requirement. . Other than these personnel, production managers, supervisors and quality checking inspectors and specialized professionals for designing assist us. For other processes, we have logistics and transportation personnel, sales and marketing managers, warehouse managers and skilled workmen. Our team members enable us to manufacture products not only as per industry standards but also at the same time as per what our client's specifications.

Meeting With The Client's Requirements Client satisfaction is our priority and we give our best efforts in maintaining our priority at all fronts. All the products that we manufacture are custom made. These are made as per the specifications and requirements we receive from clients.

RESOURCES The entire shopfloor of 70,000+ sq ft is dedicated towards providing world class solutions to our customers. Our well equipped in-house machine shop and in-house inspection facility helps in achieving highest standards of quality in manufacturing and provide world class products to our customer. Our pan India presence with offices at strategic locations helps in providing timely and efficient service to customers. A dedicated research and development team enables us to keep up with latest development in technology and meet market demands.

INNOVATIONS K-Three Electronics is a company that can be best described as an innovative, vibrant and energetic organization that is dedicated towards providing new technologies at affordable costs. The company in India to manufacture ‘Plastic Component By Injection Moulding Machine’ with 5-point toggle type clamping mechanism, K-Three Electronics use also the foremost plastic injection moulding machine manufacturer to plastic refrigerator parts for Indian market. The journey from ‘Moulds to Moulding’ has been exciting, full of challenges and rewards.

BELIEF Our ethos as an organization is based on the simple yet effective ideals of Quality, Ethics and Efficiency. We take immense pride in the patronage of our customers, support of an excellent staff and the faithful association of our strategic partners.

Our strength lies in:

POWERFUL LEADERSHIP 

Company headed by a graduate mechanical engineer with gold medals.



The owner is having a long practical experience with SLMManeklal Industries, a giant in its own time. This company was having technical collaboration with Toshiba-Japan for plastic injection moulding machines, Kautex-Germany for Blow Moulding Machines, Pinette Emidecau-France for hydraulic presses, SLM-Switzerland for Blowers, vacuum pumps and many more. The owner worked as production, design and service engineer gaining vast knowledge over a

period of 9 years. 

At K-Three Electronics, manufacturing is a hobby and in built with personal interests of every one in organization. R & D CAPABILITY:



Analytical capability for design enabling R & D capability keeping pace with latest technologies.

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Knowledge gained over years of experience is put into our products to give user friendly operations with long service life and minimum down time. There are no short cuts in manufacturing processes. The right material and right treatment to components.

CHAPTER 3 PLASTIC MANUFACTURING VIA INJECTION MOULDING PROCESS

A BRIEF STUDY ON PLASTIC INJECTION MOLDING PROCESS

3.0 INTRODUCTION Injection molding is the most commonly used manufacturing process for the fabrication of plastic parts. A wide variety of products are manufactured using injection molding, which vary greatly in their size, complexity, and application. The injection molding process requires the use of an injection molding machine, raw plastic material, and a mold. The plastic is melted in the injection molding machine and then injected into the mold, where it cools and solidifies into the final part. The steps in this process are described in greater detail in the next section.

Fig. 1.1 Injection molding overview Injection molding is used to produce thin-walled plastic parts for a wide variety of applications, one of the most common being plastic housings. Plastic housing is a thin-walled enclosure, often requiring many ribs and bosses on the interior. These housings are used in a variety of products including household appliances, consumer electronics, power tools, and as automotive dashboards. Other common thin-walled products include different types of open containers, such as buckets. Injection molding is also used to produce several everyday items such as toothbrushes or small plastic toys. Many medical devices, including valves and syringes, are manufactured using injection molding as well.

3.1 INJECTION MOLDING-OVERVIEW Injection molding is a manufacturing process for producing parts from both thermoplastic and thermosetting plastic materials. Material is fed into a heated barrel, mixed, and forced into a mold cavity where it cools and hardens to the configuration of the mold cavity. After a product is designed, usually by an industrial designer or an engineer, molds are made by a mold maker (or toolmaker) from metal, usually either steel or aluminum, and precision-machined to form the features of the desired part. Injection molding is widely used for manufacturing a variety of parts, from the smallest component to entire body panels of cars.

Fig. 1.2 Schematic Diagram of Plastic Injection molding

3.2. PROCESS CHARACTERISTICS 

Utilizes a ram or screw-type plunger to force molten plastic material into a mold cavity



Produces a solid or open-ended shape which has conformed to the contour of the mold



Uses thermoplastic or thermo set materials



Produces a parting line, sprue, and gate marks



Ejector pin marks are usually present

3.3 HISTORY& DEVELOPMENT The first man-made plastic was invented in Britain in 1851 by Alexander Parkes. He publicly demonstrated it at the 1862 International Exhibition in London; calling the material

he produced "Parkesine." Derived from cellulose, Parkesine could be heated, molded, and retain its shape when cooled. It was, however, expensive to produce, prone to cracking, and highly flammable. In 1868, American inventor John Wesley Hyat developed a plastic material he named Celluloid, improving on Parkes' invention so that it could be processed into finished form. Together with his brother Isaiah, Hyatt patented the first injection molding machine in 1872. This machine was relatively simple compared to machines in use today. It worked like a large hypodermic needle, using a plunger to inject plastic through a heated cylinder into a mold. The industry progressed slowly over the years, producing products such as collar stays, butons, and hair combs. The industry expanded rapidly in the 1940s because World War II created a huge demand for inexpensive, mass-produced products. In 1946, American inventor James Watson Hendry built the first screw injection machine, which allowed much more precise control over the speed of injection and the quality of articles produced. This machine also allowed material to be mixed before injection, so that colored or recycled plastic could be added to virgin material and mixed thoroughly before being injected. Today screw injection machines account for the vast majority of all injection machines. In the 1970s, Hendry went on to develop the first gas-assisted injection molding process, which permitted the production of complex, hollow articles that cooled quickly. This greatly improved design flexibility as well as the strength and finish of manufactured parts while reducing production time, cost, weight and waste. The plastic injection molding industry has evolved over the years from producing combs and buttons to producing a vast array of products for many industries including automotive, medical, aerospace, consumer products, toys, plumbing, packaging, and construction.

3.4 PROCESS CYCLE

The process cycle for injection molding is very short, typically between 2 seconds and 2 minutes, and consists of the following four stages:

1. Clamping - Prior to the injection of the material into the mold, the two halves of the mold must first be securely closed by the clamping unit. Each half of the mold is attached to the injection molding machine and one half is allowed to slide. The hydraulically powered clamping unit pushes the mold halves together and exerts sufficient force to keep the mold securely closed while the material is injected. The time required to close and clamp the mold is dependent upon the machine - larger machines (those with greater clamping forces) will require more time. This time can be estimated from the dry cycle time of the machine.

2. Injection - The raw plastic material, usually in the form of pellets, is fed into the injection molding machine, and advanced towards the mold by the injection unit. During this process, the material is melted by heat and pressure. The molten plastic is then injected into the mold very quickly and the buildup of pressure packs and holds the material. The amount of material that is injected is referred to as the shot. The injection time is difficult to calculate accurately due to the complex and changing flow of the molten plastic into the mold. However, the injection time can be estimated by the shot volume, injection pressure, and injection power.

3. Cooling - The molten plastic that is inside the mold begins to cool as soon as it makes contact with the interior mold surfaces. As the plastic cools, it will solidify into the shape of the desired part. However, during cooling some shrinkage of the part may occur. The packing of material in the injection stage allows additional material to flow into the mold and reduce the amount of visible shrinkage. The mold can not be opened until the required cooling time has elapsed. The cooling time can be estimated from several thermodynamic properties of the plastic and the maximum wall thickness of the part. 4. Ejection - After sufficient time has passed, the cooled part may be ejected from the mold by the ejection system, which is attached to the rear half of the mold. When the mold is opened, a mechanism is used to push the part out of the mold. Force must be applied to eject

the part because during cooling the part shrinks and adheres to the mold. In order to facilitate the ejection of the part, a mold release agent can be sprayed onto the surfaces of the mold cavity prior to injection of the material. The time that is required to open the mold and eject the part can be estimated from the dry cycle time of the machine and should include time for the part to fall free of the mold. Once the part is ejected, the mold can be clamped shut for the next shot to be injected.

Fig.2.1 Injection molded part. After the injection molding cycle, some post processing is typically required. During cooling, the material in the channels of the mold will solidify attached to the part. This excess material, along with any flash that has occurred, must be trimmed from the part, typically by using cutters. For some types of material, such as thermoplastics, the scrap material that results from this trimming can be recycled by being placed into a plastic grinder, also called regrind machines or granulators, which regrinds the scrap material into pellets. Due to some degradation of the material properties, the regrind must be mixed with raw material in the proper regrind ratio to be reused in the injection molding process.

3.5 MACHINERY & EQUIPMENT

Injection molding machines consist of a material hopper, an injection ram or screwtype plunger, and a heating unit. They are also known as presses, they hold the molds in which the components are shaped. Presses are rated by tonnage, which expresses the amount of clamping force that the machine can exert. This force keeps the mold closed during the injection process. Tonnage can vary from less than 5 tons to 6000 tons, with the higher figures used in comparatively few manufacturing operations. The total clamp force needed is determined by the projected area of the part being molded. This projected area is multiplied by a clamp force of from 2 to 8 tons for each square inch of the projected areas. As a rule of thumb, 4 or 5 tons/in2 can be used for most products. If the plastic material is very stiff, it will require more injection pressure to fill the mold, thus more clamp tonnage to hold the mold closed. The required force can also be determined by the material used and the size of the part, larger parts require higher clamping force.

Fig.2.2 Injection Molding Machine. Injection molding machines have many components and are available in different configurations, including a horizontal configuration and a vertical configuration. However, regardless of their design, all injection molding machines utilize a power source, injection unit, mold assembly, and clamping unit to perform the four stages of the process cycle.

3.6 POWER REQUIREMENTS

The power required for this process of injection molding depends on many things and varies between materials used. Manufacturing Processes Reference Guide states that the power requirements depend on "a material's specific gravity, melting point, thermal conductivity, part size, and molding rate." Below is a table from page 243 of the same reference as previously mentioned which best illustrates the characteristics relevant to the power required for the most commonly used materials.

Specific

Melting

Gravity

(°F)

Epoxy

1.12 to 1.24

248

Phenolic

1.34 to 1.95

248

Nylon

1.01 to 1.15

381 to 509

Material

Polyethylene 0.91 to 0.965

230 to 243

Polystyrene

338

1.04 to 1.07

Point

Table 1 Power Requirements.

3.7 INJECTION UNIT The injection unit is responsible for both heating and injecting the material into the mold. The first part of this unit is the hopper, a large container into which the raw plastic is poured. The hopper has an open bottom, which allows the material to feed into the barrel. The barrel contains the mechanism for heating and injecting the material into the mold. This mechanism is usually a ram injector or a reciprocating screw. A ram injector forces the material forward through a heated section with a ram or plunger that is usually hydraulically powered. Today, the more common technique is the use of a reciprocating screw. A reciprocating screw moves the material forward by both rotating and sliding axially, being powered by either a hydraulic or electric motor. The material enters the grooves of the screw from the hopper and is advanced towards the mold as the screw rotates. While it is advanced, the material is melted by pressure, friction, and additional heaters that surround the reciprocating screw. The molten plastic is then injected very quickly into the mold through the nozzle at the end of the barrel by the buildup of pressure and the forward action of the screw. This increasing pressure allows the material to be packed and forcibly held in the mold. Once the material has solidified inside the mold, the screw can retract and fill with more material for the next shot.

Fig.2.3 Injection molding machine - Injection unit.

3.8 CLAMPING UNIT Prior to the injection of the molten plastic into the mold, the two halves of the mold must first be securely closed by the clamping unit. When the mold is attached to the injection molding machine, each half is fixed to a large plate, called a platen. The front half of the mold, called the mold cavity, is mounted to a stationary platen and aligns with the nozzle of the injection unit. The rear half of the mold, called the mold core, is mounted to a movable platen, which slides along the tie bars. The hydraulically powered clamping motor actuates clamping bars that push the moveable platen towards the stationary platen and exert sufficient force to keep the mold securely closed while the material is injected and subsequently cools. After the required cooling time, the mold is then opened by the clamping motor. An ejection system, which is attached to the rear half of the mold, is actuated by the ejector bar and pushes the solidified part out of the open cavity.

Fig.2.4 Injection molding machine - Clamping unit.

3.9 LUBRICATION AND COOLING Obviously, the mold must be cooled in order for the production to take place. Because of the heat capacity, inexpensiveness, and availability of water, water is used as the primary cooling agent. To cool the mold, water can be channeled through the mold to account for quick cooling times. Usually a colder mold is more efficient because this allows for faster cycle times. However, this is not always true because crystalline materials require the opposite: a warmer mold and lengthier cycle time.

3.2.0 MACHINE SPECIFICATIONS Injection molding machines are typically characterized by the tonnage of the clamp force they provide. The required clamp force is determined by the projected area of the parts in the mold and the pressure with which the material is injected. Therefore, a larger part will require a larger clamping force. Also, certain materials that require high injection pressures may require higher tonnage machines. The size of the part must also comply with other

machine specifications, such as shot capacity, clamp stroke, minimum mold thickness, and platen

size.

Injection molded parts can vary greatly in size and therefore require these measures to cover a very large range. As a result, injection molding machines are designed to each accommodate a small range of this larger spectrum of values. Sample specifications are shown below for three different models (Babyplast, Powerline, and Maxima) of injection molding machine that are manufactured by Cincinnati Milacron. Clamp force (ton) Shot capacity (oz.) Clamp stroke (in.) Min. mold thickness (in.) Platen size (in.)

Babyplast 6.6 0.13 - 0.50 4.33 1.18 2.95 x 2.95

Powerline 330 8 - 34 23.6 7.9

40.55 x 40.55 122.0 x 106.3

Table 2 Machine Specifications.

Fig.2.5 Injection molding machine.

3.2.1 TOOLING

Maxima 4400 413 - 1054 133.8 31.5

The injection molding process uses molds, typically made of steel or aluminum, as the custom tooling. The mold has many components, but can be split into two halves. Each half is attached inside the injection molding machine and the rear half is allowed to slide so that the mold can be opened and closed along the mold's parting line. The two main components of the mold are the mold core and the mold cavity. When the mold is closed, the space between the mold core and the mold cavity forms the part cavity, that will be filled with molten plastic to create the desired part. Multiple-cavity molds are sometimes used, in which the two mold halves form several identical part cavities.

Fig.2.6 Mold overview.

3.2.2 MOLD BASE The mold core and mold cavity are each mounted to the mold base, which is then fixed to the platens inside the injection molding machine. The front half of the mold base includes a support plate, to which the mold cavity is attached, the sprue bushing, into which the material will flow from the nozzle, and a locating ring, in order to align the mold base with the nozzle. The rear half of the mold base includes the ejection system, to which the mold core is attached, and a support plate. When the clamping unit separates the mold halves, the ejector bar actuates the ejection system. The ejector bar pushes the ejector plate forward

inside the ejector box, which in turn pushes the ejector pins into the molded part. The ejector pins push the solidified part out of the open mold cavity.

Fig.2.7 Mold base.

3.2.3 MOLD CHANNELS In order for the molten plastic to flow into the mold cavities, several channels are integrated into the mold design. First, the molten plastic enters the mold through the sprue. Additional channels, called runners, carry the molten plastic from the sprue to all of the cavities that must be filled. At the end of each runner, the molten plastic enters the cavity through a gate which directs the flow. The molten plastic that solidifies inside these runners is attached to the part and must be separated after the part has been ejected from the mold. However, sometimes hot runner systems are used which independently heat the channels, allowing the contained material to be melted and detached from the part. Another type of channel that is built into the mold is cooling channels. These channels allow water to flow through the mold walls, adjacent to the cavity, and cool the molten plastic.

Fig.2.8 Mold channels.

3.2.4 MOLD DESIGN In addition to runners and gates, there are many other design issues that must be considered in the design of the molds. Firstly, the mold must allow the molten plastic to flow easily into all of the cavities. Equally important is the removal of the solidified part from the mold, so a draft angle must be applied to the mold walls. The design of the mold must also accommodate any complex features on the part, such as undercuts or threads, which will

require additional mold pieces. Most of these devices slide into the part cavity through the side of the mold, and are therefore known as slides, or side-actions. The most common type of side-action is a side-core which enables an external undercut to be molded. Other devices enter through the end of the mold along the parting direction, such as internal core lifters, which can form an internal undercut. To mold threads into the part, an unscrewing device is needed, which can rotate out of the mold after the threads have been formed.

Fig.3.1 Mold – Closed.

Fig.3.2 Mold - Exploded view.

Fig.3.3 Standard two plates tooling – core and cavity are inserts in a mold base – "Family mold" of 5 different parts.

The mold consists of two primary components, the injection mold (A plate) and the ejector mold (B plate). Plastic resin enters the mold through a sprue in the injection mold, the sprue bushing is to seal tightly against the nozzle of the injection barrel of the molding machine and to allow molten plastic to flow from the barrel into the mold, also known as cavity. The sprue bushing directs the molten plastic to the cavity images through channels that are machined into the faces of the A and B plates. These channels allow plastic to run

along them, so they are referred to as runners. The molten plastic flows through the runner and enters one or more specialized gates and into the cavity geometry to form the desired part. The amount of resin required to fill the sprue, runner and cavities of a mold is a shot. Trapped air in the mold can escape through air vents that are ground into the parting line of the mold. If the trapped air is not allowed to escape, it is compressed by the pressure of the incoming material and is squeezed into the corners of the cavity, where it prevents filling and causes other defects as well. The air can become so compressed that it ignites and burns the surrounding plastic material. To allow for removal of the molded part from the mold, the mold features must not overhang one another in the direction that the mold opens, unless parts of the mold are designed to move from between such overhangs when the mold opens (utilizing components called Lifters). Sides of the part that appear parallel with the direction of draw (The axis of the cored position (hole) or insert is parallel to the up and down movement of the mold as it opens and closes) are typically angled slightly with (draft) to ease release of the part from the mold. Insufficient draft can cause deformation or damage. The draft required for mold release is primarily dependent on the depth of the cavity: the deeper the cavity, the more draft necessary. Shrinkage must also be taken into account when determining the draft required. If the skin is too thin, then the molded part will tend to shrink onto the cores that form them while cooling, and cling to those cores or part may warp, twist, blister or crack when the cavity is pulled away. The mold is usually designed so that the molded part reliably remains on the ejector (B) side of the mold when it opens, and draws the runner and the sprue out of the (A) side along with the parts. The part then falls freely when ejected from the (B) side. Tunnel gates, also known as submarine or mold gate, is located below the parting line or mold surface. The opening is machined into the surface of the mold on the parting line. The molded part is cut (by the mold) from the runner system on ejection from the mold. Ejector pins, also known as knockout pin, is a circular pin placed in either half of the mold (usually the ejector half) which pushes the finished molded product, or runner system out of a mold.

The standard method of cooling is passing a coolant (usually water) through a series of holes drilled through the mold plates and connected by hoses to form a continuous pathway. The coolant absorbs heat from the mold (which has absorbed heat from the hot plastic) and keeps the mold at a proper temperature to solidify the plastic at the most efficient rate. To ease maintenance and venting, cavities and cores are divided into pieces, called inserts, and sub-assemblies, also called inserts, blocks, or chase blocks. By substituting interchangeable inserts, one mold may make several variations of the same part. More complex parts are formed using more complex molds. These may have sections called slides that move into a cavity perpendicular to the draw direction, to form overhanging part features. When the mold is opened, the slides are pulled away from the plastic part by using stationary “angle pins” on the stationary mold half. These pins enter a slot in the slides and cause the slides to move backward when the moving half of the mold opens. The part is then ejected and the mold closes. The closing action of the mold causes the slides to move forward along the angle pins. Some molds allow previously molded parts to be reinserted to allow a new plastic layer to form around the first part. This is often referred to as over molding. This system can allow for production of one-piece tires and wheels. 2-shot or multi-shot molds are designed to "over mold" within a single molding cycle and must be processed on specialized injection molding machines with two or more injection units. This process is actually an injection molding process performed twice. In the first step, the base color material is molded into a basic shape. Then the second material is injection-molded into the remaining open spaces. That space is then filled during the second injection step with a material of a different color. A mold can produce several copies of the same parts in a single "shot". The number of "impressions" in the mold of that part is often incorrectly referred to as cavitations. A tool with one impression will often be called a single impression (cavity) mold. A mold with 2 or more cavities of the same parts will likely be referred to as multiple impression (cavity) mold. Some extremely high production volume molds (like those for bottle caps) can have over 128 cavities. In some cases multiple cavity tooling will mold a series of different parts in the same tool. Some toolmakers call these molds family molds as all the parts are related.

3.2.5 DESIGN RULES MAXIMUM WALL THICKNESS:



Decrease the maximum wall thickness of a part to shorten the cycle time (injection time and cooling time specifically) and reduce the part volume



INCORRECT

CORRECT

Part with thick walls

Part redesigned with thin walls

Uniform wall thickness will ensure uniform cooling and reduce defects

INCORRECT

CORRECT

Non-uniform wall thickness (t1 ≠ t2)

Uniform wall thickness (t1 = t2)

CORNERS:



Round corners to reduce stress concentrations and fracture



Inner radius should be at least the thickness of the walls

INCORRECT

CORRECT

Sharp corner

Rounded corner

DRAFT:

Apply a draft angle of 1° - 2° to all walls parallel to the parting direction to facilitate



removing the part from the mold.

INCORRECT

CORRECT

No draft angle

Draft angle ()

RIBS: 

Add ribs for structural support, rather than increasing the wall thickness INCORRECT

CORRECT

Thick wall of thickness t 

Thin wall of thickness t with ribs

Orient ribs perpendicular to the axis about which bending may occur

INCORRECT

CORRECT

Incorrect rib direction under load F Correct rib direction under load F  Thickness of ribs should be 50-60% of the walls to which they are attached 

Height of ribs should be less than three times the wall thickness



Round the corners at the point of attachment



Apply a draft angle of at least 0.25°

INCORRECT

CORRECT

Thick rib of thickness t

Thin rib of thickness t

Close up of ribs BOSSES: 

Wall thickness of bosses should be no more than 60% of the main wall thickness



Radius at the base should be at least 25% of the main wall thickness



Should be supported by ribs that connect to adjacent walls or by gussets at the base.



INCORRECT

CORRECT

Isolated boss

Isolated boss with ribs (left) or gussets (right)

If a boss must be placed near a corner, it should be isolated using ribs.

INCORRECT

CORRECT

Boss in corner

Ribbed boss in corner

UNDERCUTS: Minimize the number of external undercuts

 o

External undercuts require side-cores which add to the tooling cost

o

Some simple external undercuts can be molded by relocating the parting line

Simple external undercut o

Mold cannot separate

New parting line allows undercut

Redesigning a feature can remove an external undercut

Part with hinge

Hinge requires side-core

Redesigned hinge New hinge can be molded Minimize the number of internal undercuts

 o

Internal undercuts often require internal core lifters which add to the tooling cost

o

Designing an opening in the side of a part can allow a side-core to form an internal undercut

Internal undercut accessible from the side o Redesigning a part can remove an internal undercut

Part with internal undercut

 o

Mold cannot separate

Part redesigned with slot New part can be molded Minimize number of side-action directions Additional side-action directions will limit the number of possible cavities in the mold

THREADS 

If possible, features with external threads should be oriented perpendicular to the

parting direction.



Threaded features that are parallel to the parting direction will require an unscrewing

device, which greatly adds to the tooling cost.

3.2.6 MATERIALS There are many types of materials that may be used in the injection molding process. Most polymers may be used, including all thermoplastics, some thermosets, and some elastomers. When these materials are used in the injection molding process, their raw form is usually small pellets or a fine powder. Also, colorants may be added in the process to control the color of the final part. The selection of a material for creating injection molded parts is not solely based upon the desired characteristics of the final part. While each material has different properties that will affect the strength and function of the final part, these properties also dictate the parameters used in processing these materials. Each material requires a different set of processing parameters in the injection molding process, including the injection temperature, injection pressure, mold temperature, ejection temperature, and cycle time. A comparison of some commonly used materials is shown below (Follow the links to search the material library).

Material name Acetal

Abbreviation POM

Trade names Description Applications Celcon, Delrin, Strong, rigid, Bearings, Hostaform, excellent cams, gears,

Lucel

Acrylic

PMMA

Acrylonitrile Butadiene Styrene

ABS

Cellulose Acetate

CA

Polyamide (Nylon)

6 PA6

Polyamide (Nylon)

6/6 PA6/6

fatigue resistance, excellent creep resistance, chemical resistance, moisture resistance, naturally opaque white, low/medium cost Diakon, Rigid, brittle, Oroglas, scratch Lucite, resistant, Plexiglas transparent, optical clarity, low/medium cost Cycolac, Strong, Magnum, flexible, low Novodur, mold shrinkage Terluran (tight tolerances), chemical resistance, electroplating capability, naturally opaque, low/medium cost Dexel, Tough, Cellidor, transparent, Setilithe high cost Akulon, High strength, Ultramid, fatigue Grilon resistance, chemical resistance, low creep, low friction, almost opaque/white, medium/high cost Kopa, Zytel, High strength, Radilon fatigue resistance,

handles, plumbing components, rollers, rotors, slide guides, valves

Display stands, knobs, lenses, light housings, panels, reflectors, signs, shelves, trays Automotive (consoles, panels, trim, vents), boxes, gauges, housings, inhalors, toys

Handles, eyeglass frames Bearings, bushings, gears, rollers, wheels

Handles, levers, small housings, zip

Polyamide (Nylon)

11+12 PA11+12

Polycarbonate

Polyester Thermoplastic

Polyether Sulphone

PC

- PBT, PET

PES

Rilsan, Grilamid

chemical resistance, low creep, low friction, almost opaque/white, medium/high cost High strength, fatigue resistance, chemical resistance, low creep, low friction, almost opaque to clear, very high cost

Calibre, Lexan, Very tough, Makrolon temperature resistance, dimensional stability, transparent, high cost

ties

Air filters, eyeglass frames, safety masks

Automotive (panels, lenses, consoles), bottles, containers, housings, light covers, reflectors, safety helmets and shields Celanex, Rigid, heat Automotive Crastin, Lupox, resistance, (filters, Rynite, Valox chemical handles, resistance, pumps), medium/high bearings, cams, cost electrical components (connectors, sensors), gears, housings, rollers, switches, valves Victrex, Udel Tough, very Valves high chemical resistance, clear, very high

Polyetheretherketon e

PEEKEEK

Polyetherimide

PEI

Ultem

Polyethylene - Low LDPE Density

Alkathene, Escorene, Novex

Polyethylene - High HDPE Density

Eraclene, Hostalen, Stamylan

Polyphenylene Oxide

PPO

Noryl, Thermocomp, Vamporan

Polyphenylene Sulphide

PPS

Ryton, Fortron

cost Strong, thermal stability, chemical resistance, abrasion resistance, low moisture absorption Heat resistance, flame resistance, transparent (amber color)

Aircraft components, electrical connectors, pump impellers, seals

Electrical components (connectors, boards, switches), covers, sheilds, surgical tools Lightweight, Kitchenware, tough and housings, flexible, covers, and excellent containers chemical resistance, natural waxy appearance, low cost Tough and stiff, Chair seats, excellent housings, chemical covers, and resistance, containers natural waxy appearance, low cost Tough, heat Automotive resistance, (housings, flame panels), resistance, electrical dimensional components, stability, low housings, water plumbing absorption, components electroplating capability, high cost Very high Bearings, strength, heat covers, fuel resistance, system brown, very components, high cost guides,

Polypropylene

Polystyrene General purpose

PP

- GPPS

Polystyrene - High HIPS impact

Novolen, Appryl, Escorene

Lacqrene, Styron, Solarene Polystyrol, Kostil, Polystar

Polyvinyl Chloride - PVC Plasticised

Welvic, Varlan

Polyvinyl Chloride UPVC – Rigid

Polycol, Trosiplast

Styrene Acrylonitrile

SAN

Luran, Arpylene, Starex

Thermoplastic Elastomer/Rubber

TPE/R

Hytrel, Santoprene, Sarlink

switches, and shields Lightweight, Automotive heat resistance, (bumpers, high chemical covers, trim), resistance, bottles, caps, scratch crates, handles, resistance, housings natural waxy appearance, tough and stiff, low cost. Brittle, Cosmetics transparent, packaging, low cost pens Impact Electronic strength, housings, food rigidity, containers, toys toughness, dimensional stability, naturally translucent, low cost Tough, Electrical flexible, flame insulation, resistance, housewares, transparent or medical tubing, opaque, low shoe soles, toys cost Tough, Outdoor flexible, flame applications resistance, (drains, transparent or fittings, opaque, low gutters) cost Stiff, brittle, Housewares, chemical knobs, syringes resistance, heat resistance, hydrolytically stable, transparent, low cost Tough, Bushings, flexible, high electrical cost components, seals, washers

Table 3: Materials.

3.2.7 MOLDING DEFECTS Injection molding is a complex technology with possible production problems. They can either be caused by defects in the molds or more often by part processing (molding)

Molding Defects Blister

Alternative Name Blistering

Descriptions

Causes

Raised or layered Tool or material is too hot, often caused zone on surface of by a lack of cooling around the tool or a

Burn marks

Air

the part faulty heater Burn/ Black or brown Tool lacks venting, injection speed is too

Gas

Burn/ burnt areas on the high

Dieseling

part

located

furthest from where

at

points gate

or

air

is

Color

Colour

trapped Localized change Masterbatch isn't mixing properly, or the

streaks (US)

streaks

of color/colour

(UK)

material has run out and it's starting to come through as natural only. Previous colored material "dragging" in nozzle or check valve. like Contamination of the material e.g. PP

Delaminatio

Thin

n

layers formed in mixed with ABS, very dangerous if the

mica

part wall

part is being used for a safety critical application as the material has very little strength

Flash

Burrs

when

delaminated

as

the

materials cannot bond Excess material in Mold is over packed or parting line on the thin

layer tool is damaged, too much injection

exceeding normal speed/material injected, clamping force

part geometry Embedded

Embedded

too low. Can also be caused by dirt and

contaminants around tooling surfaces. particle Particles on the tool surface,

Foreign

contaminate particulates

(burnt material or contaminated material or foreign debris in

s

other)

Flow marks

Flow lines

embedded the barrel, or too much shear heat burning

in the part the material prior to injection Directionally "off Injection speeds too slow (the plastic has tone" wavy lines cooled down too much during injection, or patterns

injection speeds must be set as fast as you

can get away with at all times) Deformed part by Poor tool design, gate position or runner.

Jetting

turbulent flow of Injection speed set too high. Knit Lines

Weld lines

material Small lines on the Caused by the melt-front flowing around backside of core an object standing proud in a plastic part pins or windows as well as at the end of fill where the in parts that look melt-front comes together again. Can be like just lines.

minimized or eliminated with a moldflow study when the mold is in design phase. Once the mold is made and the gate is placed one can only minimize this flaw by changing the melt and the mold

Polymer

polymer

degradation

breakdown

temperature. Excess water in the granules, excessive from temperatures in barrel

hydrolysis, Sink marks

[sinks]

oxidation etc. Localized depression

Holding time/pressure too low, cooling (In time too short, with sprueless hot runners

thicker zones)

this can also be caused by the gate temperature being set too high. Excessive

Short shot

Non-fill

Splay marks

Short mold Splash

/ Partial part Circular

material or thick wall thickness. Lack of material, injection speed or pressure too low, mold too cold pattern Moisture in the material, usually when

mark Silver

gate hygroscopic resins are dried improperly.

/ around

caused by hot gas

streaks Stringiness

Stringing

Trapping of gas in "rib" areas due to excessive injection velocity in these

areas. Material too hot. String like remain Nozzle temperature too high. Gate hasn't from previous shot frozen off transfer

in

shot Empty

Voids

new space Lack

of

holding

pressure

(holding

within part (Air pressure is used to pack out the part pocket)

during the holding time). Filling to fast, not allowing the edges of the part to set up. Also mold may be out of registration (when the two halves don't center properly and part walls are not the same

Weld line

Knit line / Discolored

thickness). line Mold/material temperatures set too low

Meld line / where two flow (the material is cold when they meet, so Transfer

Warping

fronts meet

they don't bond). Point between injection

line

and transfer (to packing and holding) too

Twisting

early. Cooling is too short, material is too hot,

Distorted part

lack of cooling around the tool, incorrect water

temperatures

(the

parts

bow

inwards towards the hot side of the tool) Uneven shrinking between areas of the part Table 4: Molding Defects.

3.2.8 TOLERANCES AND SURFACES: Molding tolerance is a specified allowance on the deviation in parameters such as dimensions, weights, shapes, or angles, etc. To maximize control in setting tolerances there is usually a minimum and maximum limit on thickness, based on the process used. [36] Injection

molding typically is capable of tolerances equivalent to an IT Grade of about 9–14. The possible tolerance of a thermoplastic or a thermoset is ±0.008 to ±0.002 inches. Surface finishes of two to four micro inches or beter are can be obtained. Rough or pebbled surfaces are also possible.

Molding Type

Typica l

Possible

Thermoplastic

±0.008

±0.002

Thermoset

±0.008

±0.002

Table 5: Tolerances.

3.2.9 COSTING & ESTIMATION: MATERIAL COST: The material cost is determined by the weight of material that is required and the unit price of that material. The weight of material is clearly a result of the part volume and material density; however, the part's maximum wall thickness can also play a role. The weight of material that is required includes the material that fills the channels of the mold. The size of those channels, and hence the amount of material, is largely determined by the thickness of the part.

PRODUCTION COST: The production cost is primarily calculated from the hourly rate and the cycle time. The hourly rate is proportional to the size of the injection molding machine being used, so it is important to understand how the part design affects machine selection. Injection molding machines are typically referred to by the tonnage of the clamping force they provide. The

required clamping force is determined by the projected area of the part and the pressure with which the material is injected. Therefore, a larger part will require a larger clamping force, and hence a more expensive machine. Also, certain materials that require high injection pressures may require higher tonnage machines. The size of the part must also comply with other machine specifications, such as clamp stroke, platen size, and shot capacity. The cycle time can be broken down into the injection time, cooling time, and resetting time. By reducing any of these times, the production cost will be lowered. The injection time can be decreased by reducing the maximum wall thickness of the part and the part volume. The cooling time is also decreased for lower wall thicknesses, as they require less time to cool all the way through. Several thermodynamic properties of the material also affect the cooling time. Lastly, the resetting time depends on the machine size and the part size. A larger part will require larger motions from the machine to open, close, and eject the part, and a larger machine requires more time to perform these operations.

TOOLING COST: The tooling cost has two main components - the mold base and the machining of the cavities. The cost of the mold base is primarily controlled by the size of the part's envelope. A larger part requires a larger, more expensive, mold base. The cost of machining the cavities is affected by nearly every aspect of the part's geometry. The primary cost driver is the size of the cavity that must be machined, measured by the projected area of the cavity (equal to the projected area of the part and projected holes) and its depth. Any other elements that will require additional machining time will add to the cost, including the feature count, parting surface, side-cores, lifters, unscrewing devices, tolerance, and surface roughness. One final consideration is the number of side-action directions, which can indirectly affect the cost. The additional cost for side-cores is determined by how many are used. However, the number of directions can restrict the number of cavities that can be included in the mold. For example, the mold for a part which requires 3 side-action directions can only contain 2 cavities. There is no direct cost added, but it is possible that the use of more cavities could provide further savings.

3.3.0 APPLICATIONS Injection molding is used to create many things such as wire spools, packaging, bottle caps,

automotive

dashboards,

pocket

combs,,refrigerators

parts,washing

machine

parts,television parts and most other plastic products available today. Injection molding is the most common method of part manufacturing. It is ideal for producing high volumes of the same object. Some advantages of injection molding are high production rates, repeatable high tolerances, and the ability to use a wide range of materials, low labor cost, minimal scrap losses, and little need to finish parts after molding. Some disadvantages of this process are expensive equipment investment, potentially high running costs, and the need to design moldable parts. Most polymers may be used, including all thermoplastics, some thermo sets, and some elastomers. In 1995 there were approximately 18,000 different materials available for injection molding and that number was increasing at an average rate of 750 per year. The available materials are alloys or blends of previously developed materials meaning that product designers can choose from a vast selection of materials, one that has exactly the right properties. Materials are chosen based on the strength and function required for the final part but also each material has different parameters for molding that must be taken into account.[8] Common polymers like Epoxy and phenolic are examples of thermosetting plastics while nylon, polyethylene, and polystyrene are thermoplastic.

GENERAL PLASTIC INJECTION MOLDING APPLICATIONS  Aerospace components  Automotive components  Avionics components  Cable assemblies  Computer electronics

 Electronics components  Encapsulations  Engineering prototypes  Geophysics  Instrumentation  Marketing samples  Material quality testing  Medical & dental products  Medical laboratories  Model shops, toys, hobby  New product design & development  R&D labs  Test specimens

3.3.1 THE FUTURE OF INJECTION MOLDING Some of the new tendencies and technology in injection molding are the electric injection machines and the gas assisted injection molding. The electric machines have several advantages over the old design of the conventional injection machine. It runs silent, its operating cost is less, and they are more accurate and stable.

Fig.6.1 An all-electrical Injection Machine.

CHAPTER 4 RESEACH &METHODOLOGY

PROJECT OBJECTIVES To analyze the behaviour of Thermoplastic material during the production cycle from the filling phase until the ejection phase To determine the factors that cause quality defects in injection moulding process. To study how to achieve the minimum production cycle time by reduction of rejections, To study how to overcome the quality defects based on the factors that have been discovered. To collect the information, findings, to analyze and draw conclusion. To explain the documentation used at the various stages of the plastic manufacturing via injection moulding To study and highlight the area where injection moulding process needs improvement in the rejection phases

SCOPE

 To understand the plastic manufacturing via injection moulding at KThree Electronics Pvt Ltd. 

Find out the productivity of plastic component.

 To help the company to determine how they make their production increase and reduce rejection 

To determine various parameters to collect information through questionnaire of employer.

 Injection moulding is a heat transfer process. We inject a molten liquid into a metal mould and transfer the heat into the metal, where it is transferred into the cooling media.Plastic injection moulding is the most important plastic production method. It is also the most complex processes due to the many delicate adjustments. The flow of liquid during the process may affect the final quality of the product. So, this experiment is to determine the initial process parameter setting for the injection moulding process.

RESEARCH METHODOLOGY

Definition

Research in common parlance refers to a search for knowledge. The advanced learner’s dictionary of current English lays down the meaning of research as “a careful investigation of enquiry specially through search for new facts in any branch of knowledge.” The systematic approach concerning generalization and the formulation of a theory is also research. The purpose of research is to discover answers to questions through the application of scientific procedures.

Research Design

“A research design is the arrangement of conditions for collection and analysis of data in a manner that aims to combine relevance to the research purpose with economy in procedure.” - JOHN.W.BEST Research may be defined as “any organized inquiry designed and carried out to provide information for solving a problem”. - EMORY “Research is essentially an investigation, a recording and an analysis of evidence for the purpose of gaining knowledge”. - ROBERT ROSS

Descriptive Research Design Descriptive research design studies are those studies, which are concerned with describing the character of a group. The researcher makes a plan of the study his research work. That will enable the researcher to save and resources such a plan of study or blue print or study is called a research design.

Data Collection

The study was based on questionnaire method and also collect the data by observation method There are two types of data collection:  

Primary data Secondary data

Primary data The primary data are those, which are collected a fresh and for the first time happen to be original in character. It has been collected through a Questionnaire and personal interview.

Secondary data Secondary data are those which have already been collected by someone else and which have already been passed through the stratified process. It has collected through the manuals, journals & Internet.

Research design and collection of data In this study the research methodology followed descriptive in nature Descriptive research design studies are those studies, which are concerned with describing the character of a group. To study the plastic manufacturing process through injection moulding. Secondary and primary data both have been used to study the rejection of product and analysis the factors leading to rejections and suggest ways or method of reducing such rejection

Primary Data Primary data has been collected through questionnaires. The factor leading to rejection are determined through observation and questionaries’ are also used to client information as to the reason for the rejection. I take 100 samples each of 5 products for my research work.

Secondary Data Secondary data have been collected through websites of the company and also collected from manuals, journals & Internet.

Research Instrument



Questionnaire containing both closed and open ended questions

Tools for Analysis

Along with the usual statistical tools such as tables, percentages, bar charts, I have used observation method for analyzing the efficiency of production of plastic parts. I also used six sigma method to find out the rejection.

Six sigma process analysis Based on literature review, this research aims at 1. 2. 3. 4. 5. 6.

To utilize six sigma methodology in performing the study. To study the “Black dot” rejects utilizing QC tools at the Identified production lines. To identify the root causes of the “Black dot” rejects. To recommend actions to improve the Black dot rejects and Sigma level.

A Case Study The application of Six-Sigma methodology is a statistical analysis approach to quality management. In this approch the rejection ratio of injection Moulding production department in a company K-THREE ELECTRONICS , Greater Noida was analyzed statistically using DMAIC methodology and suggestions for quality improvement will be made to the department.

DMAIC – Define stage Define the process Before the process can be investigated, all circumstances have to be defined. Such circumstances are often described as SIPOC (Suppliers, Inputs, Process, Outputs and Customers). The circumstances around the Moulding of electronics parts are listed in chronological order below. Suppliers -Material supplier, Reliance Inputs -Material, PMMA (Acrylic) Process -Receive PMMA and load into hopper -

Dry PMMA Feed PMMA into Moulding machine Mould Jar Deliver Jar Outputs -Jar Customers - external customers

18 Identify the current reject problem The in-line rejection based on the part produced. Table 1. In- line rejection based on part produced Product Model In-line reject unit CV- 3004 2284 TV-3004 1033 TFR- 1501 895 RC-1501 371 RJ-0801 338 FTC-100 ml 239 FTC-02 231 FTC-06 202 FTC-28 ml 186 BT-204 177 FB-101 175 FB-501 92 SB-031 84 RB-503 72 Others 543

In-line (k-unit) Percentage 2.284 33.01 1.033 14.92 0.895 12.93 0.371 5.36 0.338 4.88 0.239 3.45 0.231 3.34 0.202 2.92 0.186 2.69 0.177 2.56 0.175 2.53 0.092 1.33 0.084 1.21 0.072 1.04 0.543 7.85

Acc. 33.01 47.93 60.86 66.22 71.10 74.55 77.89 80.81 83.50 86.06 88.59 89.92 91.13 92.17 100

Table 1 shows the rejection data for injection Moulding for the month of FEB 2017. This data shows the highest rejection ratio compared to the previous months rejection data ). Figure 1 shows the Pareto diagram for the particular part rejects based on the code name. The result shows that, part named COVER TV-3004 have the highest rejection rate for the month which is 2284 units and contributes 33.01 % of the total rejection rate. Since the part has the highest rejection rate it has been taken as the studying element for the research.

Six Sigma Methodology In A Plastic Injection Molding Industry K - UNIT

19

ACC - (%)

100

2.5

90 80

2

70 60

1.5

50 40

1

30 20 10

0.5

0

0

In – line rejection Figure1: In- line rejection based on part produced DMAIC- Measure stage Data was collected for 4 months continuously from March to June 2017 for output line reject that occurred in the Moulding part production that focused on the production of part named COVER TV-3004 to track down the problem encountered by this particular part. Since there are four machines producing the same part, the reject data were collected for each machine. These data were used to calculate defect per million opportunities (DPMO) for each month. Table 2 shows the total output, reject quantity, DPMO and sigma level for each month from March to June 2017. Table 2: Total output and Sigma level Month March April May June TOTAL

Output 149760 149760 149760 149760 599040

Machine(reject quantity) E01 E03 E04 E06 60 935 910 405 53 937 908 367 59 946 878 398 23 914 495 291 195 3732 3191 1461

TotalRej/mth DPMO 2310 3084.9 2265 3024.8 2281 3046.2 1723 2301.1 8579

SIGMA 4.2356 4.2420 4.2397 4.3301

Sigma level from the above database for four months March 17 to June 17. Basic steps to Compute Sigma level Identify the CTQ Define defect opportunities Collect data on defects Compute DPMO Use Standard formula to arrive at the Sigma level Formula used to compute Sigma level Total pieces manufactured=P Total rejection =R Total CTQ =O Defect per unit(DPU) =R/P DPO =DPU/CTQ 6 =DPO×10 DPMO Sigma level ( Z ) =0.8406+√{29.37-2.221ln(DPMO)} Computed Sigma level for June 2009 Total pieces manufactured, P = 149760 Total rejection, R = 2310 Total CTQ, O = 5 DPU, R/P = 0.0154247 DPO, DPU/CTQ = 0.0030849 6 DPO×10 = 3084.9 DPMO, Sigma level б = 0.8406+√{29.37-2.22ln(3084.9)} = 4.2356 A bar graph was constructed as in Figure 2, for each month based on Reject Quantity. Figure 2 shows that the highest rejection rate was identified in the month March 2017 meanwhile for other moths the data collected shows small variations.

Six Sigma Methodology In A Plastic Injection Molding Industry 2500

21

120

2400 2300

100

2200

80

2100 2000

60

1900

40

1800 1700

Total Rej/m Acc(%)

20

1600 1500

0 mar

Aprl

May

June

MONTH Figure 2: In-line rejection from month June to September 2009 Based on the data in table 2, the sigma level for the process were calculated and illustrated as in figure 3. The figure 3 explains that the sigma level from the month March to June ranging from 4.2356 to 4.3301. This shows the average sigma level for the whole process is 4.262. The lowest sigma level was recorded for the month March and the highest sigma level was recorded on the month June. Since the sigma level for month March has the lowest sigma level, the studies or research will be focused on the month March. This data will used to track down the problem that contributes to highest reject on the part.

22

SIGMA 4.34 4.33 4.32 4.31 4.3 4.29 4.28 4.27 4.26 4.25 4.24 4.23 4.22

4.3301

SIGMA

4.2356

MAR

4.242

APR

4.2397

MAY

JUNE

MONTH Figure 3: Sigma level from month March to June 2017 DMAIC- Analyze stage

Table 3 shows the defect type’s data for the month March 2017 and Figure 4 illustrate the Pareto diagram for this particular data. As mentioned before, there are four machines which produce the same part which known as Cover TV-3004 and the data for defects were collected based on machines. This is to identify the machine E03 which contributes to the highest rejection rate. The defects which are recorded in Table 3 are the comment types of defects which normally occur on plastic parts which produced by using injection Moulding process. Figure 4 explains that black dot defects are the major contributor for the rejection rate for the month June which contributes almost 40% of the total rejects compared to other defects. If defect data compared by machine, still black dot contributes the highest defects compared to others and for the machines, machine E03 contributes to highest black dot defect compared to other machines. As a measure to track down the problem machine E03

will be used to analyze the root cause for the black dot defects since it shows the highest rejection rate and the analyze data will be used as references for other machine.

Six Sigma Methodology In A Plastic Injection Molding Industry

23

Table 3:- Reject data based on the defect type for month MARCH 2017 Cover Tv-3004 Defect Black Dot Scratches Dented Burn mark Oily/Dirty Short Mold Sink Mark Parting Burr White mark Silver Mark Others

E01 38 2 0 0 14 2 2 1 0 0 1

Machine No E03 E04 347 273 304 245 160 165 0 117 43 50 64 10 8 42 8 6 0 0 0 2 0 0

No of Defects

E06 SubTotal 268 926 144 645 22 347 0 117 8 115 3 79 8 60 0 15 3 3 0 2 0 1 Total = 2310

Percentage 40.09 27.92 15.02 5.06 4.98 3.42 2.60 0.65 0.13 0.09 0.04

Acc. 40.09 68.01 83.03 88.09 93.07 96.49 99.09 99.74 99.87 99.96 100

ACC (%)

1000

120

900

100

800

700 600 500 400 300 200 100 0

80 60 40 20 0

Figure 4: Reject data based on the defect type for month March 2017

Potential causes for high defects occurred in part Cover Tv Analyzing the rejects based on models indicates that the highest percentage of defects occurred in model COVER TV-3004. Figure 6 shows the potential causes for high defects. The number of defects is high when there are new models being introduced. It may be due to the operators not given enough training or no special training for the operator to understand the correct method to produce the part. Besides that, the high defects might contributed by the machines. The machines Might operate by new technicians that lack of training or experience. This will lead to misjudging in solving the problem during the machining process. Stressful environment also can lead to high rejects. It’s a human nature, where when workers find that the working environment stressful, this will lead to dissatisfaction in working condition and at the same time it also leads to high defects. Besides that the method or standard operation principles also can lead to high defects. Methods or SOP for the particular process might be varying from the actual SOP for the process and this will contributes to wrong machine setting or operation parameters.

Six Sigma Methodology In A Plastic Injection Molding Industry High Defect Lack of Training

No special Training

Do not understand the Procedure

Stressful Work environment

New Model

Poor job satisfaction

Machine Operation and condition

New Work

Figure 6: Potential causes for high defects Root causes analysis In order to determine the exact and most likely causes of major defects, a Brainstorming section was carried out with the Quality Engineer. Through the brainstorming section, all possible causes including major and minor causes were listed in the cause and effect diagram. The following section will discuss on the root causes for black dot defects.

Root causes analysis for Black dot defect The wrong part defect is caused by five major factors, which are machine, environment, man (operator), method and the material. Figure 7 shows the cause and effect diagram for the black dot defect. Machines are one of the factors that must be given black dot consideration. The machine contributes a lot of possibilities to

25

black dot rejection defect. Examples, without proper parameter setting it will result to a carbonized screw. Aging machines also can lead to defects. Maintenance also plays and important part because, without maintenance the performance of machine will be affected and the desired output could not been gained. When an operator does not have enough experience and practice, it is quite obvious that the operator produces more defects than the others. Defects might occur when jobs carried out without guidance of leader or without any instruction. Besides that, number of defect will increase when untrained operator or new operators are assigned to do the job. The work method is another major cause of the problem. It was found that the operator did not know the correct method set the machine and the parameters but only followed the instructions without knowing the correct method. As a result the operator

can lead to black dot defect or other rejection. Working environment was another cause for the defect. It is based on company policy where, there are two shift with 12hours working period each in the production department. This can cause the operator to loose concentration, become tired and bored doing the job. As a result the organizations will hire new operator who do not have any knowledge or experience in the production line. Besides that, a material as an important medium in injection molding process also contributes to some major defects. Examples, when material are contaminated with other foreign particles it will effects the properties of the part and at the same time it lead to major defects.

METHOD

MAN Lack of skill of No proper die service cleaning screw PP material not suitable & barrel Barrel

No schedule for pp cleaning

No proper parting line Cleaning BLACK DOT Material with dust & impurities

Barrel was dirty Screw was carbonized

Dust around the machine & uncomforted working environment

MATERIAL

ENVIRONMENT

Die was dirty

MACHINE

Figure 7: Root causes analysis for black dot Summary on the analysis As the conclusion for the analysis stage, the major defect found were black dot and several problems were identified as the main problems causes high defects in injection Moulding line. The main problem identified from the analyze section is the machine. This due to the data which colleted indicates that the major problem for each machine is the black dot. This shows that the major defect might cause by the machine. Although there are

other factors affecting the reject problems, the main consideration has given to the machine factor. The next section will discuss about suggestion for improvement.

DMAIC- Improve stage After collecting and analyze the data, the identified defect was the black dot defect which caused major quality problem in the injection Moulding line. Cause and effect diagram was also drawn to identify the causes of major defects. From here suggestions recommended to reduce the defects was Screw and barrel cleaning.

Screw and barrel cleaning Screw cleaning The injection screw was carbonized before cleaning, which was used to mould the cover tv-3004. After a request as a suggestion to the engineering group to clean the screw. Sand paper and some chemical solvents were used to clean the screw. Most of the dirt was identified from the material which was carbonized because of overheated in the barrel. The overheated material will stick on the screw and will released slowly each time injection and caused for the black dot on the surface of the Cover Tv-3004.

Barrel cleaning It was seen at the time of study the condition of machine which was not cleaned properly where a lot of scrap material surround the tie bar and hydraulic unit area. This condition will lead to a situation where the foreign materials or scrap material will mixed original material and at the same time leads to black dot and other defects. After carry out the cleaning activity on the machine, the machine was covered with a plastic to make sure no dirt or dust affects the machine condition. Figure 8 shows a run chart that represent the Black Dot trend before and after screw cleaning process for machine E03. Based on the figure 8, the trend before cleaning shows that the defects per day from 7th June to 23rd June is higher than the trend after cleaning where the cleaning process perform on 24th of June. This clearly shows that the machine factor plays an important role and it needs to maintain for time of period in order to eliminate or reduce the black dot problem. The chart itself concludes that one of the main causes for the black dot is the machine condition. These results will be used by the production in charge member to perform continues action and at the same time improve the sigma level for the process.

Table 4:- Total no. of rejection per day from 07 June13 with Screw Barrel cleaning on 24 June 13 Round Jar-3004

Machine No E03

DATE 07-June-17 08- June -17 09- June -17 10- June -17 11- June -17 12- June 17 13- June -17 14- June -17 15- June -17

REJ/day 22 40 147 68 33 72 43 64 31

16- June -17 17 June -17 18- June -17 19- June -17 20- June -17 21- June -17 22- June -17 23- June -17 24- June -17 25- June -17 26- June -17 27- June -17 28- June -17 29- June -17 30- June -17 01-July -17 02- July -17 03- July -17 04- July -17 05- July -17 06- July -17 07- July -17 08- July -17

34 46 69 129 71 92 79 53 Screw barrel cleaning 32 46 28 21 33 13 26 41 8 12 4 6 6 14

Six Sigma Methodology In A Plastic Injection Molding Industry

REJ/day 160 140 120 100 80 60 REJ/day

40 20

07/Se p/0908/Se p/0 909/Se p/0 910/Sep/0911/Sep/0912/Se p/0913/Se p/0914/Se p/0 915/Se p/0 916/Sep/0917/Sep/0918/Se p/0919/Se p/0920/Se p/0 921/Se p/0 922/Sep/0923/Sep/0924/Se p/0925/Se p/0926/Se p/0 927/Se p/0 928/Sep/0929/Sep/0930/Se p/0901/Oct/0902/Oct/0903/Oct/0904/Oct/0905/Oct/0906/Oct/0907/Oct/0908/Oct/09

0

Days

Figure 8: black dot trend before and after screw cleaning for machine E03 From the analysis done for this project, a conclusion can be made that machine condition is the major contributor for the black dot problem. Since the engineering group member cannot clean the injection screw or the barrel every day, a new cleaning material agent was proposed or suggested to solve this problem.

Summary on improve stage Based on the suggestion given, the rejection rate can be reduced and at the same time the sigma level can be improve.

DMAIC- Control stage Control stage is another important stage before completing DMAIC methodologies. This stage will describe the step taken to control. One of the comment types of quality tool used is the control chart. Control charts is another popular statistical process control tools which is used in this stage because it can detect abnormal variation in the process. In this operation we can use c-chart because c-chart can monitors the number of defects per inspection unit. Besides that c-chart also will monitor multiple types of quality in a product.

SAMPLING METHOD Survey is done by random sampling method.

SAMPLE SIZE DEFECTIVE PRODUCT 1. Machine Sample : E01 Product Sample : 100 Product type : Cover TV 2. Machine Sample : E02 Product Sample : 100 Product type : TFR 3. Machine Sample : E03 Product Sample : 100 Product type : Tray Veg 4. Machine Sample : E04 Product Sample : 100 Product type : pp 5. Machine Sample : E05 Product Sample : 100 Product type : TV Back Cover

SAMPLE AREA K-Three Electronics Pvt Ltd, Greater Noida

MODE OF ANALYSIS The instrument used for data collection was in the form of questionnaire. The questionnaire was used as it facilitates the tabulation and analysis of the data to be collected. The data collected was subjected to simple frequency distribution and percentage analysis.

CHAPTER 5 DATA ANALYSIS AND INERPRETATION

QUES1: What are the prouducts manufacture by k-three electronics and each of have what percentage of total production 

Cover tv



Tray fresh room



Tray veg



Drainer



Duct



Water outlet pipe

Products

Production %

Cover tv

25

Tray fresh room

20

Tray veg

25

Drainer

18

Duct

6

Water outlet pipe

6

QUES2: Which type of defect has more percentage share in cover tv. 

Black Dot



Short moulding



Knob Shutter



Silver Marks



Warpage



Cracks



Painting

Defect

Rejection %

Black Dots

42

Short Moulding

16

Knob Shutter

3

Silver Marks

8

Warpage

10

Cracks

16

Painting

5

Conclusion Acc to this table 42% rejection comes from black dots in cover TV. If we can control this rejection then we will increase the production rate and also increase the profit for the company

QUES3: Which type of defect has more percentage share in Tray veg.



Black Dot



Short moulding



Knob Shutter



Silver Marks



Warpage



Cracks



painting

Defect

Rejection %

Black Dots

25

Short Moulding

18

Knob Shutter

1

Silver Marks

15

Warpage

5

Cracks

17

Painting

8

Conclusion According to this table we have seen that most of the rejection comes from black dots and short moulding it as a major issue for the organization. Production department shouid take corrective action for rejection

QUES4: which type of defect has more percentage share in TFR. 

Black Dot



Short moulding



Shrinkage



Silver Marks



Warpage



Cracks



painting

Defect

Rejection %

Black Dots

32

Short Moulding

16

Shrinkage

5

Silver Marks

15

Warpage

11

Cracks

16

Painting

5

Conclusion Acc to the table most of the rejection come from black dots on the product it is about 32%of the total rejection and by which production can not meet the demad.

QUES5: Which type of defect has more percentage share in washing machine parts.



Black Dot



Short moulding



Silver Marks



Cracks



Painting

Defects

Rejection

Black dots

15

Short moulding

21

Silver marks

11

Cracks

11

Painting

7

QUES6: which type of defect has more percentage share in AC Parts.



Black Dot



Short moulding



Silver Marks



Cracks



painting

QUES 7: Major cause of rejection due to defective material in injection moulding process in k-three electronics. 

Unskilled labor



Method



Material



Environment



Machine

Cause of defect

Percentage

Unskilled labour

28

Material

15

Environment

3

machine

44

Method

10

Conclusion Acc to this graph machine is major cause of rejection in the organization it is about 44% of the total cause of rejection and also 28 %comes from unskilled labour it’s a major problem for company

Ques8: What are percentage of rejection in each product of total rejection? 

Cover tv



Tray fresh room



Tray veg



Drainer



Duct



Water outlet pipe





Products

Production %

Cover tv

24

Tray fresh room

16

Tray veg

35

Drainer

10

Duct

5

Water outlet pipe

10

 

Findings 

K-Three Electronics has adopted a better method of plastic manufacturing via injection moulding processs.



In this study the mostly of rejection in plastic parts due to black spot in k-three electronics



In this study we apply a six sigma method to know about defect and we find that when we increase the sigma level then we can reduce the defect rate.



Rejection based analysis:  37 % of rejection comes from black spot  27% of rejection come from the short moulding defect.  18 %comes from the cracks defect.  only 11% & 7% comes from silver marks and painting



Data based on questionnaire or observation  It helps to find out the defect in the moulded parts.  BY which we know to why rejection occur in the process.

 

To understand the percentage of defect in moulded parts By which we can increase the production by reducing in rejection.



By using we can easily reduce the defect in the moulding process that lead production should be increase then productivity will be increase



Top 3 manufacturing challenges are as follows : Quality  Reduce rejection

Conclusion From the study of plastic injection moulding companies case study it is found that Six Sigma as an innovative approach supports organizations to detect and remove defects and improve

their business performance considerably. It also shows that Six Sigma’s expanding influence on industry as Because of the remarkable benefits the Six Sigma approach has demonstrated in various plastic injection moulding companies, This study also reviewed the effect of six sigma tools in various Phases of DMAIC and its benefits achieved in form reduction in rejection rate and increasing quality level by increasing six sigma value The result of this study proved that the quality of product in a plastic industry can be improved by using Six Sigma approach. Adapting Six Sigma as a part of business strategy certainly helps the organizations to accomplish sustainable growth.

This paper studies the plastic filling defects using design of experiment approach. Then the six sigma method was applied to find the optimal values for defect. It was concluded from this study that injection speed affect the most the inverted label defect. The lower the injection speed the better the results are obtained regarding the inverted label. It was also found that the injection pressure and Baking pressure have significant effect on the incomplete filling defect. The injection speed of 300 CCm/Sec and the injection pressure of 2000 bar, these results would enhance the quality level for the company which in turn increases customer satisfaction. Moreover, material utilization and energy consumption are improved, which in turn reduce the production cost for the company and increase profit.

This study focused on the inverted label and incomplete plastic filling Because Pareto chart proved to be the most important two major defects. It can be extended to other defects and also for improving overall quality. In future work optimum parameters for characteristics like hardness, tensile strength and good surface finish of different materials may also obtain the methodology adopted in this research is limited in term of finding the relationship between multiple quality characteristics and process parameters. This is due to the limited capability of Taguchi method. Grey relational analysis might be a good candidate to obtain the optimum processing parameters combination for multiple quality characteristics simultaneously. The

adopted methodology can also be used in the part design process in order to minimize variation in output.

The Present study focuses on the quality improvement of one of the major defect in Plastic Injection Moulding of components. One of the main defect which is the causes of the rejection is “Black spot” (small dark particles on the surface of the opaque parts), on the appearance of the product. In order to study the problem a research has been carried out by studying the literature review on TQM, Six Sigma and other references for this analysis and research method. The objectives of this paper is to identify the problem of Black specks, which reduces quality, due to defects in manufactured parts, and to suggest measures for the improvement in the Injection Moulding operation using Six-Sigma DMAIC methodology. This paper encompasses introduction and implementation of Six Sigma tools for removing the Black specks in the Injection Moulding process. Following suggestions are given a. clean Barrel and use cleaning agent for cleaning Screw and Barrel c. sand paper can also be used Most of the dirt was identified from the material which was carbonized because of overheated in the barrel. The overheated material will stick on the screw and will release slowly each time injection and caused for the black specks on the surface

RECOMMENDATIONS After analyzing the collected data, the following recommendations were made to improve the present plastic manufacturing or reduction in rejection in the organization.



First of all the management should review their manufacturing policy and look

for the areas of improvement for ensuring the best quality. 

Management should structure and systematically organize the entire

manufacturing processes.



Management system should facilitate faster, unbiased, accurate and reliable

towards any employer. 

Manufacturing management system should helps to reduce the time-per-piece

and cost-per-piece 

Production management system should communicate every person of the

company whether it is in lower hierarchy or in upper hierarchy this lead to benefit in production of the company.  Recruitment management system should maintain an automated active database for the defective parts and then take a faster corrective action towards problem t and increasing the efficiency of the manufacturing processes.

Limitations of the Study Certain limitations were also faced during the project. •

One of the biggest limitations is the Time Line. A period of 2 months is not sufficient to fully understand how the company works.

•

Availability of data; there are some data which are confidential to the company which are not shared if needed.

•

Candidates were reluctant to talk at the higher management level.

•

Intense industry competition often results in low profit margins.

•

Mould costs are high

•

Moulding machinery and auxiliary equipment costs are high.

•

Lack of knowledge about the fundamentals of the process causes problems.

•

Lack of knowledge about the long term properties of the materials may result in long-term failures

•

People asked lot of counter question so convincing them was a major task People did not disclose much about their employee details

QUESTIONAIRE BASED ON OBSERVATION QUES1: Which type of defect has more percentage share in cover tv? 

Black Dot



Short moulding



Knob Shutter



Silver Marks



Warpage



Cracks



Painting

QUES2: Which type of defect has more percentage share in Tray veg?



Black Dot



Short moulding



Knob Shutter



Silver Marks



Warpage



Cracks



painting

QUES3: which type of defect has more percentage share in TFR. 

Black Dot



Short moulding



Knob Shutter



Silver Marks



Warpage



Cracks



painting

QUES4: which type of defect has more percentage share in AC Parts.



Black Dot



Short moulding



Silver Marks



Cracks



painting

QUES5: which type of defect has more percentage share in AC Parts.



Black Dot



Short moulding



Silver Marks



Cracks



painting

QUES 6: Major cause of rejection in injection moulding process of k-three electronics. 

Unskilled labor



Method



Material



Environment



Machine

QUES7: What are the prouducts manufacture by k-three electronics and each of have what percentage of total production 

Cover tv



Tray fresh room



Tray veg



Drainer



Duct



Water outlet pipe

Ques8: What are percentage of rejection in each product of total rejection? 

Cover tv



Tray fresh room



Tray veg



Drainer



Duct



Water outlet pipe

BIBLIOGRAPHY

WEBSITE www.scribd.com https://www.slideshare.net/naumanasif1/injection-molding-process https://en.wikipedia.org/wiki/Injection_moulding https://www.emis.com/php/companyprofile/IN/K_Three_Electronics_Pvt_Ltd_en_3540247.html https://www.scribd.com/document/179911827/MOULDING-DEFECTS-1-PDF MAGAZINES Business India Business World Course Books of B.tech (ME) Plastic Today