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

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

Let’s get started!

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