Injection Moulding Module 3

Dates: 21st October, 2019 - 24th October, 2019 (4 days)

Duration: 4 days

Location: 7 Centre Court, Blyry Business and Commercial Park, Athlone.

Accreditation: Injection Moulding Process Control

Full Fee: €1495 for our 4-day course includes course manual, lunch and refreshments.

Course code: 5N3037

Programme overview

This Injection Moulding course focuses on techniques used to understand and “map” the injection moulding process, reducing moulding inconsistency by understanding its causes and effects. A strong emphasis is placed on giving participants the practical skills to apply both SPC and troubleshooting techniques.

There will be home study on most nights to check understanding.

Where possible we restrict Injection Moulding course numbers to just six places using three machines.

Safety Shoes – Required for this course

We can deliver a shorter tailored programme at our centre in Athlone for you/ or on-site if you have injection moulding capability there.

 

 

Content

Course Content Day 1:
Introduction and recap on prior knowledge
Troubleshooting and common faults/ discussion
Troubleshooting software (PICAT)
Machine, Mould, Material familiarisation

Day 2:
Practical 1:
7-Point plan to set up clamp/injection end
discussion re: problems at set up/ Ways of solving
Moulding cycle optimisation
Using SPC
Case Studies

Practical 2:
SPC monitoring of m/c to gather data for day 3
A spec. sheet will be provided with tolerances/ cycle times etc.

Day 3:
Discussion on Day 2 outcomes
Cp/Cpk

Practical 3:
Optimise mould, calculate Cp/Cpk again
Review to improve output
Optimising machine cycle
Case Studies

Practical 4:
Change mould and repeat optimising exercise
Calculate Cp / Cpk

Day 4:
Discussion and Feedback
Case Studies

Start the same machine up from cold and note differences in set-up, i.e.sizes, weights, pressures, etc. If time permits zero and start again. Analysis of SPC in classroom

Who is the course for

This course is designed for technical staff with a strong working knowledge of the injection moulding process and systematic troubleshooting techniques, who wish to understand and increase their control of the moulding process to increase part quality and consistency. In order to enrol on this course, trainees must have already completed our Injection Moulding Module 2 programme.

Learning outcomes

At the end of the course trainees should be able to:

  1. List causes of shot to shot variation caused by the injection moulding machine hardware
  2. List causes of shot to shot variation caused by the plastic material
  3. List causes of shot to shot variation caused by the injection moulding process parameters
  4. Describe what the terms Cp, CpK, Standard Deviation, Average and Range mean.
  5. Write out the equation to calculate the Process Capability Index Cp
  6. Write out the equation to calculate the Process Capability Index CpK
  7. Calculate the Cp and CpK results from a given set of data.
  8. Work out the Standard Deviation from a given set of data using MS Excel.
  9. List the common errors made during data collection, part weight measurements.
  10. Describe in detail the steps to complete a full tool trial on an injection mould using scientific moulding principles
  11. Demonstrate the steps to complete a full tool trial on an injection mould using scientific moulding principles
  12. Explain the causes of the following defects in terms of Plastic Material causes, Part Design causes and process parameter causes: Flash, Burn Marks, Short Shots, Sink Marks, Weld Lines, Bubbles, Voids and Gate Blush.
  13. Demonstrate how to prevent/ cure the following moulding defects using data from the moulding process/ pressure curve data to analyse and cure the fault:

Trainer Profile

Steve O’ Leary has delivered training in Injection Moulding for First Polymer Training since 2000, initially joining FPT Skillnet as the Training Center Manager. Previous to this he worked as an Extrusion/ Injection Moulding Engineer with Boston Scientific in Galway, Extrusion Technician and Extrusion Supervisor with Sherwood Medical in Tullamore (currently Medtronic Tullamore) and as an Injection Moulding Technician with Tubex in Nenagh, Co. Tipperary. He graduated from Athlone IT having studied Plastics Engineering from 1988 to 1992.

Find out how to achieve a Major Award in Injection Moulding (Level 5)

This programme is a QQI component (minor) award, certified at Level 5 on the national framework of qualifications – see www.nfq.ie  and is a mandatory component of major award 5M3080 – Plastics Injection Moulding.

 Protection for Enrolled Learners Policy

For further details on our training equipment please click here

 

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