Course Outline Day 1 Polymers and Plastics: - History and definition of plastics - Molecular weight and molecular weight distributions - Physical and morphological properties of plastics - Thermal transitions in plastics - Analysis and testing of plastics - Common Commercial plastics, additives and fillers. Plastic Flow: - Non Newtonian fluids - Flow through channels and pipes - Temperature dependence of viscosity - Shear rate dependence of viscosity Injection Molding: - Introduction to injection molding, - Types of machines and auxiliary equipment - The molding machine, screw and barrel - Terminology of machine specifications - Defects in moldings Development of robust injection molding processes: - The injection molding cycle and process parameters - In mold rheology or viscosity curves - Gate seal tests - Molding area diagram - Cooling study Day 2 Use of software for developing the injection molding process - Introduction - Databases available - Worksheets - Documentation of issues - Tracking iterations to final production Molds and Mold design: - Mold components and types of molds - Types of runners and gates - Mold cooling and venting - Hot runner systems - Materials of construction Plastic Part design: - Mold filling requirements, L/T ratio, number of gates - Shrinkage and warpage - Flow leaders and restrictors - Wall thickness and corners - Structural considerations - Press fits and snap fits - Mechanical fasteners Quality Control: - Variation and normal distributions - X-bar and R charts, histograms - Control limits and control charts - Process capability and six sigma - Statistical Quality Control - Statistical Process Control Day 3 The Unique Challenges Facing Injection Molding Linking Experimental Design with Process Validation, 6 Sigma, and QS-9000 How Experimental Design Links with Scientific Molding What to do Before Conducting any Experiments What is Experimental Design? Factors (process conditions) Levels. Ranges of Interest Responses (customer requirements) What are the Benefits? Test Time Reduction Understanding Relationships Case Studies from Injection Molding What are the Steps? Planning Determining Tests Conducting Tests Analysis Confirmation Tabled Orthogonal Arrays Day 4 Using Technical Knowledge and the Internet to Select Starting Points Graphical Analysis Bar Charts (Pareto) Main Effect Plots Contour Plots, 3-D Plots How to Get Started with Applications at Your Facility Statistical Analysis (using software) ANOVA MLR Prediction Equations D-optimal Designs Co-optimization of Multiple Customer Requirements Group Exercise Using an Injection Molding Process   __________________________________________________________ Guarantee of Satisfaction/Refunds for Cancellations Launsby Consulting seminars and products are fully guaranteed. If any of our seminars do not meet your needs, contact us and we will promptly send you a refund. If any of our products fail to meet the highest standards of quality and performance, please return them in like-new condition in their original packing materials, and we will send you a refund. When cancellations are made at least 14 days prior to the seminar date, we will refund your registration fee minus a $100 processing fee. Copyright © 2008 Launsby Consulting. All rights reserved. Last Updated 10/011/08 If you experience problems with this site please email us. Six Sigma® is a registered Trademark of Motorola Inc. Statapult® is a registered Trademark of Air Academy Associates