In order to differentiate yourself from other low cost competition, you have to innovate and keep up with more and more complex production processes : for example, two-tone injection, adding inserts, or very small pieces.
Another example of understanding the laminate printing machine for the pharmaceutical industry.
You are taking risks on margins because the scrap rate and production rates are not at the expected levels : improve with your teams your knowledge of your machines and their performance limits and the quality produced.
Give yourself the means to control them.
The notable improvement of these result indicators is linked to methods listed here :
– Experimental plans according to the TAGUCHI method,
as just using them is nothing if you do not have the competence and experience of adaptation and inter-usage of them, coupled with an experience of the processes themselves.
These methods can also be used in silicone injection, thermoplastic elastomer and in complicated processes such as : semi-conductors, paper making, printing, food, or any other process that incorporates a multitude of parameters.
The experimental plans method helps to identify the main parameters to stabilize or intensify the result ; the Taguchi method considerably reduces the number of trials needed to gain sufficient knowledge of the process and to forecast its reactions.
We have used these methods in several plastic injection processes and have described the results of one of them in detail :
The reject rate is leveled off and reduced from 7% to 5% in the whole of the factory in 2 months.
Other gains :
– reduction in time cycle : increase in output
– homogenization of the temperature
– accuracy in measurements
– mastering dilatation
The human factor should not be forgotten as even in the most highly automated procedures, it still plays a large role : participation of staff to regulate this improves the understanding of the methods installed.
Do you want applied advise on Taguchi method ?
The customer in complex packaging for the pharmaceutical industry was having difficulty controlling the process and quality produced on a special machine.
In a few days of Tagucchi’s design of experiments, he understood the effects of certain settings on the quality of the product and also that other settings had no effect.