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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.

Understanding Online Meetings…

I have seen many attempts towards the marketing of online meetings as training for production workers and I would like to define what an online meeting is and how I have seen it is best used…

Online Meetings
There are many resources available where you can conduct meetings online. In most cases, these provide an open environment where someone can display their computer screen and everyone can communicate using a phone or computer microphone. These systems typically limit the participants to 10-15 people since more participants will have difficulty communicating openly. Ultimately, this is a great way to collaborate on a project, conduct a meeting when everyone cannot get together, or meet with people working off-site. I have talked to many companies who have used this tool very effectively for collaboration.
As a training company, we use similar tools to coordinate and collaborate on projects with our employees and training partners. It is also very common for us to use these tools to demonstrate specific concepts to our customers. In most cases, we will ask our customer to show us their computer using the software so we can see what they are doing… and help them complete a specific task.
-Andy


Making Time for Training…

The other day I received a common question…

John
I know we are in need of training, my scrap is up and my production numbers could be better, but we’re so busy, it’s hard to find the time.

My Response
The important aspect is to consider is momentum. It’s similar to housekeeping… everyone has to help keeps things clean, but there is always some task which seems more important than sweeping the floor. Unfortunately, if no-one does any cleaning, the place turns into a mess. With respect to training, the same occurs. Doing a consistent amount of training each week helps you get the ball rolling forward, resulting in a slowly improving workforce. In our experience, most forms of training we promote do not consume a large amount of time to conduct. In many cases, the training can be done at short 10 or 20 minute increments if necessary.
Additional Thoughts
Since there is no quick fix to training, it is critical to ensure that your company makes slow steady efforts towards improvements as is should with all aspects of production including housekeeping, skills, procedures, maintenance, etc.
-Andy

The Future of Plastics…

Many of my friends have been asking me about the future of training as the plastics processing becomes more technical…

Plastic Processing
Plastics processing will continue to advance towards more technical and capable equipment. As with all technical advances in the industry, the need for fundamental training does not diminish… it actually increases.
For example, when molding machines went from open loop control to closed loop control, the machine did not eliminate the need for training, it increased the need. Open loop machines only had a few adjustments which could be made, and were very simple to control… closed loop machines are actually more complex and have dozens of parameters which can be changed. Now that hydraulic molding machines are giving way to all-electric molding machines, the need for training is even more critical since the possible adjustments increase even more… and these machines have a greater potential to become damaged as their power, speed, and response increase with each generation.
Likewise, blow molding and extrusion equipment are becoming more advanced with closed-loop controls with more integrated downstream equipment. As these systems advance… the need for a better understanding of both the equipment and how it processes the plastics increases as well.
Some of our customers get into employee training because the equipment is so advanced, that they become completely dependent on engineers to coordinate the technology, yet they lose the less technical employees who had the fundamental understanding of plastics processing with turnover and retirement. The best approach is to train all your employees about the fundamentals as well as advanced training for technicians. 
-Andy 



Can Gas Entrapment Cause Poor Surface Finish?

An engineer emailed me this question yesterday,,,

John
My setup technician believes gas entrapment is the cause for poor surface finish on a particular process. When we clean the vents, the appearance improves, but does this make sense, or is there something else causing this?

My Response
Although most people associate burning or dieseling with gas entrapment, there are many other defects that can be cause by gas entrapment. Poor surface finish, flash, short shots, poor weld line strength and appearance can also result. In the case of surface finish, If the gas does not escape, it can collect at the end of the fill or it may become distributed between the mold surface and the polymer melt. When it gets between the melt and the mold surface, it typically prevents the melt from filling each contour of the mold surface resulting in a poor reproduction of the mold surface in the final molded part.
Additional Thoughts
One easy way to test this is to reduce the clamp tonnage and determine if the improved parting line venting improves the surface finish. 
-Andy

Investigating Part Warpage…

A technician asked me this question yesterday…

Jason
What is the best way to correct for part warpage?

My Response
Typically, part warpage is the result of variable shrinkage. In most cases, the variations in shrinkage causes the part to buckle, bow, or twist. Unfortunately, there are many causes which will contribute to this including mold temp, melt temp, injection speed, pack pressure, cooling time, and packing time. Additionally, both high and low settings can cause warpage for most of these parameters.
To refine my approach, I like to determine whether the part dimensions are the same, larger, or smaller than an unwarped part. It is also important to know if the part is larger or smaller at the gate, end of fill, or consistent across the entire part. This information will give you very valuable information when trying to correct for the part warpage. For example, if the part dimensions are small at the gate, yet consistent throughout the rest of the part, you can refine your troubleshooting approach to causes such as poor gate seal.
-Andy