Scrap reduction in the automotive industry
Scrap reduction in the automotive industry
Industry:
Automotive Industry
Focus:
Production of plastic injection molded parts
Challenge:
The injection molding process for a new part is causing enormous problems and the reject rate of the high-speed production has been around 70 % for several weeks. There are errors in the form of bubbles, deformations and dimensional deviations. There are many process parameters whose target settings are unknown.
Objective:
The objective is to reduce the waste to max. 10 % and in this context to determine optimal process parameter settings.
Our Solution:
Six Sigma
Project duration:
about 6-8 months
Action:
A Six Sigma project was initiated. The following summarizes the activities of the completed phases:
› Measure:
Clear definition of parameters for the evaluation of an injection molded part; Checking the suitability of the measuring system by means of Gage analyzes (continuous and discrete features) as well as determination of the output performance.
› Analysis:
Workshop on the systematic and targeted process analysis and prioritization of the cause variables, planning of a fractional factorial DoE.
› Improve:
Calculation of the required sample size and DoE, establishment of the model, verification attempt with the optimal parameters.
› Control:
Introduction of Control Charts (SPC) to monitor the significant parameters.
Results:
Reduce the reject rate to 8% through a causal process analysis and a targeted application of DoE. The functionality of the injection molding process could be determined in the form of an algorithm, which in turn allowed a derivation of the optimal parameterization.
Achieved benefit: > € 200,000, – per year
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We’re looking forward to providing you with a quote, a demo or any information about our services.