Reduction of scrap2019-07-31T13:31:30+00:00

Scrap reduction in the automotive industry

Scrap reduction in the automotive industry

Automotive Industry

Production of plastic injection molded parts


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.


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

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.


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

Let’s get started!

We’re looking forward to providing you with a quote, a demo or any information about our services.