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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.

Procedure for Checking Platen Parallelism…

To continue on a previous post regarding machine maintenance, I will answer the second question…

Tim
What is the best method of measuring platen squareness?
My Response
The most common method is to use a set of inside micrometers to measure the distance between the platens. Before you do this, you should first remove the mold, clean the platens, and use a straight edge to determine corresponding areas on the stationary and movable platen which are flat. Next, install a mold which covers at least 2/3 of the distance of the tie bars. Lastly, measure the parallelism of the platens (at each corner) when the mold is opened, closed, and under full tonnage. This will provide you with a great detail of information regarding the parallelism of the platens, the linearity of platen movement, and possible tie bar stretch.
The best method of measuring the parallelism is to use a laser system. These systems use a laser mounted perpendicular to the movable platen and a detector on the stationary platen. These systems are connected to a computer which will collect data and analyse the parallelism and linearity of movement during mold closing, and clamping. This data will give you great specific information regarding parallelism, angles, twist, and movement.
-Andy

Machine Leveling Procedures…

This morning, I received a three part question regarding machine maintenance. The first question will be addressed here…

Tim
I am now working at a plant where all the machines are all over ten years old and have not been well maintained. What is the best procedure for machine leveling?
My Response
The most common method is to place a level on the tie bars as well as across the tie bars to level each side of the machine using the adjustable feet. Many molders neglect to check both the top an bottom tie bars as well as the levelness across the tie bars. When doing this, it is worth while to purchase or rent a laser level specifically for tie bar leveling.  
The most effectiveness methods is to use a rotating laser positioned and leveled on the floor. In this method, two sensors are placed on each of the two bottom tie bars to measure the levelness of each corner. In this case, the whole clamp area can be leveled with a high degree of accuracy. After the bottom tie bars are leveled, the top tie bars should be checked in the same manner. Since these systems tend to be expensive, many molders will rent the levels or hire an expert to come in for a couple days to help level the molding machines properly.
Additional Thoughts
Since the machines are unlikely to be properly leveled, it is important to measure this once every three months for the first year to ensure the machines can maintain levelness and are not ‘walking’.
For a related post, please feel free to read: Remedy For A Walking Machine
-Andy

Blueprint Reading Skills…

I received a comment regarding a commonly overlooked skill the other day…

HT
Our company has it’s own system of part drawings so I do not believe general blueprint training applies to what we do.
My Comments
Good technical training teaches not only the specifics, but the fundamental information necessary for true understanding. 
In the situation above, having a good understanding of concepts such as how the drawing represents the physical part and how dimensions are calculated can be critical skills for good decision making. When this general understanding is combined with specific instruction on how to use in-house documents, the employee learns applicable skills along with additional information critical to good decision making.
-Andy

The Pitfalls of ‘Need-to-Know’ Training…

I heard this from a manager the other day…

Manager
Our method of training is to have a new employee shadow one of our technicians for a couple days before we let them process themselves. This method teaches the our employees what they need to know about processing, the rest they learn on-the-job.

My Thoughts
When you try to teach an employee just what they ‘need to know’ they might learn enough to be mildly effective in the workplace, but they will not learn what is truly necessary to really succeed at their job. For effective problem solving, a person needs to know the why, and not just the how. 
For example, if a die setter is told to use a torque wrench to tighten the bolts but does not know why this is important, they are very likely to just use the wrench in their hand to tighten the bolts rather than walk to the toolbox and retrieve the torque wrench.
Additionally, inadequate information can result in poor workplace safety because an uninformed employee is more likely to cut corners. Employees who reach under guards, tie off safety switches, and lit things improperly are usually just trying to save time without really understanding the consequences.
-Andy

Self-Paced vs. Self-Taught…

I was just asked this question on the phone…

JD
If I leave the training up to my people, it will never get done. I have many books, magazines, and articles available to my employees, but they never use them. What is the difference between that and self-paced training?
 
My Response
Self-Taught: This expression implies that the employee actually guides, develops, and executes their own learning program, and is motivated enough to make it work. Although you have occasionally heard stories of those who are ‘self-taught’, these highly motivated employees are extremely rare.
Self-Paced: This expression refers to employees who are given specific training, tasks, exercises, and direction, and they follow this at a pace suitable to themselves. In cases where employees have reasonable goals and objectives,  virtually every employee has the ability to learn and grow professionally… especially when they understand how it benefits them professionally.
Additional Thoughts
Basically, every employee wants to succeed at their job, but not all employees receive the training necessary to do their jobs well.
-Andy