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It is said that the manufacturing industry has a higher cost ratio than other industries, accounting for about 80%. Therefore, it is necessary to be highly cost-conscious in manufacturing. In this page, we would like to introduce some ideas for cost reduction in the manufacturing process of plastic products.
1. elimination of molding defects
The most important factor in cost reduction is the elimination of molding defects. Shortening the molding cycle in an effort to increase productivity will produce molding defects, which will result in a loss of profit. To avoid molding defects, it is necessary to understand molding defects.
Types of molding defects
Short shot - Deformation - Hiccups/voids - Jetting - Gas burning - Burrs - Destruction/whitening - Dimensional defects - Pressure marks - Weld lines - Silver streaks - Poor ejection
Short shot Molding material does not fill the mold completely and part of the molded product is missing Gas burn All surfaces of the molded product become discolored, and the flow ends and weld areas turn black due to combustion Burrs Molten resin from mold gaps and PL (parting line) Deformation Molded product becomes distorted immediately after removal from the mold Hickey/Void Air bubbles inside the molded product Weld line Air bubbles inside the molded product
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2. shorter molding cycle
Shortening the molding cycle is one of the most cost-effective measures because it directly reduces manufacturing costs, such as labor (employee wages) and expenses (utilities, factory rent, etc.). The cooling process is the most time-consuming part of the molding cycle. The manufacturing know-how is how to shorten this cooling time without producing molding defects.
Molding cycle shortening method
3ⅮCooling water pipe ・Insert molding ・Materialized silver ・Punching out molding ・Aluminum mold ・Multiple cavity molding ・High appearance molding ・2-color molding
Review of molding facilities
Moulding equipment refers to the injection moulding machine that actually performs the moulding, the ejection machine that takes them out and the camera inspection.Here, space and manpower savings can be expected.
These should be considered at the production planning stage.
Review of molding facilities
High cycle molding machine ・Extraction machine ・Camera inspection machine ・Hot runner
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