In the existing injection molding industry, we are faced with:
1. Rise in raw materials
2. Labor cost rises rapidly
3. Difficult to recruit employees
4. High mobility
5. Product price decrease
6. Industry competition is becoming increasingly fierce . questions.
Injection molding industry has entered the era of transformation, meager profit and shuffling. The management of injection molding workshop needs to establish a "scientific, perfect, systematic and standardized" operation management system, so as to achieve the working atmosphere of "everyone is in charge of everything", and the following measures and suggestions are available for the improvement of working efficiency and reduction of manpower of each post in injection molding workshop.
1, Measures to improve working efficiency and reduce manpower of upper and lower die workers
1. Do a good job in production planning and reduce the number of machine changes due to improper scheduling.
2. Reasonably set the number of ejector pin and ejector length to reduce the frequent occurrence of needle breakage in production.
3. Strengthen the cleaning, lubrication and maintenance of the mould in the production process to reduce the failure rate of the mould.
4. Strictly control the phenomenon of die pressing in the process of injection molding production and reduce the number of die dropping maintenance.
5. Use appropriate tools to take the adhesive parts of the mold, prevent the mold from being injured by human due to careless operation, and reduce the maintenance times of the lower mold.
6. Make the upper and lower mold tool car and the lifting ring waiting for work tools to locate the storage area to reduce the time to find the upper mold tools.
7. Push "fast up mold method", refine each action of up and down mold, and convert internal time into external time.
8. Reduce die locking force and end die locking speed, reduce die deformation and bruise.
9. Design the inlet of the mould water channel as a sinking hole, and use a quick joint to reduce the time of disassembling and assembling the water nozzle.
2, Measures to improve working efficiency and reduce manpower of mould testing personnel
By improving the level of mold designer, improving the working quality and efficiency of mold tester, and reducing the workload of mold tester, the purpose of reducing mold tester is achieved
1. Use the mold flow analysis software to design the mold, optimize the mold structure, improve the mold runner, gate, cooling, exhaust, demoulding and other effects.
2. Reduce the increase of the times of mold modification, repair and test caused by many mold structure problems
3. train the mold designers on injection molding technology, and fully consider the material performance, injection molding process requirements and injection quality requirements when designing the mold
4. The injection molding technology training shall be carried out for the mold testing personnel to improve the ability of the mold testing personnel to find, analyze and deal with problems, so as to improve the quality and efficiency of the mold testing and reduce the number of mold testing.
5. Specify the number of new mold test (no more than 3 times)
6. Do a good job of preparation before mold test, select a suitable injection molding machine, and conduct scientific mold test to shorten the time of mold test and reduce the modulus of test.
7. Formulate the mold testing process, standardize the mold testing requirements, clarify the purpose of mold testing, increase the responsibility of each department, and reduce the number of invalid mold testing from the management.
8. Select the personnel with rich working experience and professional knowledge who are responsible for the work to test the mold, shorten the time of test mold and increase the number of test mold sets.
3, Measures for improving working efficiency and reducing manpower of shunting personnel
1. Implement automatic and unmanned injection molding to reduce the adjustment caused by the instability of manual start-up.
2. Control the ambient temperature of the workshop to stabilize the mold temperature, material temperature and injection molding process conditions. (ring)
3. Formulate standard process conditions, arrange production machines reasonably, and ensure the repetition of process conditions. (Law)
4. Strengthen the management of injection molding process, and prohibit the operators, molders and feeders in the injection molding process. Personnel and other non-technical personnel shall adjust the machine to prevent process fluctuation and change of rubber quality. (person)
5. Do a good job in protecting the injection molding machine to ensure the repeated accuracy of the injection molding machine and the stability and reliability of the process conditions. (machine)
6. Filter cooling water to prevent abnormal quality caused by mold temperature change caused by water channel system rust. (machine)
7. Strictly control the quality of raw materials, nozzle materials and granular materials. The nozzle materials shall be recycled after screening dust to prevent adjustment caused by raw material problems. (material)
8. Do a good job in the use, maintenance and maintenance of injection mold to reduce mold failure and workload of mold transfer and machine adjustment after mold repair. Clean the greasy dirt on the mould with the special paper for wiping the mould before the trial adjustment of the mould, so as to reduce the trial time and save materials.
9. Carry out comprehensive and systematic training on injection molding technology knowledge for injection molding technicians, master the knowledge of material, machine, mold, process and defect analysis, improve their ability to analyze and deal with problems, improve their injection molding technology level and control ability of injection molding process, reduce blind machine adjustment, and take the road of scientific injection molding.
10. For special molds (such as multi neutron molds), it is necessary to mark the precautions on the molds to make the problems obvious and prevent the personnel from making mistakes.
11. Before shutdown, the material pipe shall be cleaned and then cooled to prevent that the material burning screw cannot be cleaned, and the screw cleaner shall be used to save the time for cleaning the material pipe.
4, Measures to improve working efficiency and reduce manpower of batching personnel
1. The mixing room needs to increase the number of mixers (mixers), mix materials by color and plastic material type, and equip sufficient and appropriate tools to clean the mixers, improve the efficiency of cleaning the mixers, and shorten or reduce the time and workload of cleaning the mixers.
2. If there are many mixers, multiple materials can be batched at the same time to reduce the number of batchers.
3. Change the traditional way of batching by shift, implement batching by single, make the raw material rack, and complete the materials required by the order at one time, reduce
