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This informative blog allows plastics professionals to discuss plastics training and technology. Brought to you by Routsis Training: the plastic industry's premiere training provider.

Learn and then Teach Others…

Just a quick comment today…

I am often asked how to best ensure employees are learning the information provided in hands-on training. There are methods of testing which can be used effectively, but the best method is to have your employees teach the hands-on portion to others. If someone learns how the training relates to their job, and then demonstrates that information to someone else, then the information becomes ingrained deep in their mind.

-Andy

Just Start Documenting…

I was recently asked this question…

Manager
My technicians are now excited about doing some more advanced process documentation. When should we start?
My Response
Today. You don’t have to make a big production about it, just get started with an approach which fits your companies culture.
Additional Thoughts
I have seen three approaches work with great success. 
All-In Approach – In this approach, the company starts using an entirely new machine independent process documentation system. All older process documentation sheets are systematically replaced and removed. This is the fastest way to convert, but is often the most contentious, especially with the more seasoned molders.
Dual Approach – In this approach, the company creates machine independent process documentation which is associated with the mold. Typically, the company uses this approach to allow the technicians to reference both machine dependent and machine independent documentation. This approach is typically the easiest to implement, but the most confusing with respect to which documented process is the actual standard.
Gradual Approach – In this approach, machine independent parameters are gradually added to the process documentation while machine dependent parameters are gradually removed until fully machine-independent documentation becomes commonplace. This is the most common approach I have seen in the industry.
-Andy

Again, Don’t Discount Your Employees…

Often I am approached by employees who want to improve their skills, yet their employer does not want to invest in training. Remember, each employee wants to do a good job… if they did not want to do a good job, you would not have them on your staff.

Always Nurture a Desire to Learn
When your employee is actively trying to improve their skills knowledge, pay attention because that is the type of employee motivation employers want. Your best course of action is to investigate what they want to learn and evaluate the benefit to the company. If their desired learning tract is not exactly in-line with the company goals, then try to find a similar form of training which will also benefit the company.
-Andy

Mold Trials Under Realistic Conditions…

I was recently involved in a consulting project with a common issue…

Situation
The company has purchased a new mold and trials were run. Unfortunately, the PP parts were failing performance tests and exhibiting cracking. The company was investigating the tool in hopes of determining what is different with the new tool.
Problem
Upon investigation, the tool was not much different, but they were not using a process similar to that of the production tool. They were using less than 5% of the overall cooling time to recover the next shot causing the material to become over-stressed during melting. Additionally, they were using time for 1st stage transfer causing over-packing during 1st stage fill. This creates additional molded-in stresses in the part contributing to the part failure.
Additional Thoughts
Just because you are running trials does not mean you can rush and cut corners. Always take the time to develop a good process so you can derive applicable data form your efforts.
-Andy

Why Optimize Packing Pressure…

I was asked this question during a training class…

Student
Does it really matter if we optimize the packing pressure?

My Response
Although it depends on the part geometries, an excessive packing pressure can easily add 1-3% to the overall part weight. In an commodity market, such an increase in material consumption may have a large impact on the overall profitability of the process. In many packaging markets, a 2% increase in material consumption can result in an overall profit loss.
Additional Thoughts
In today’s globally competitive market, molders should take every opportunity to improve efficiency… especially when there is no capital investment necessary. Every step in optimizing your filling, packing, cooling, recovery, and part removal results in direct increases in your overall efficiency.
-Andy