INDUSTRIAL MACHINE FINE-TUNING FOR A PLASTICS MANUFACTURER
After several months of kaizen, a leader among manufacturers of plastic components for the automotive industry had reached c.1% scrap rate which they were unable to improve any further. They approached us to help them further fine-tune one of their injection moulding machines with an ultimate goal of achieving a zero scrap rate - the holy grail of manufacturing. The particular challenge lied in investigating relationships between 50+ input parametres, thousands of process sensors, and resulting output quality.
Our solution decodes the relationships between input settings and output quality, resulting in a tuned injection-moulding machine that gets scrap rate as close to zero as technically possible.
The resulting algorithm lead to a suggestion of optimal settings and process windows for the machine that eventually led to a zero scrap rate. This had two important benefits for the plant manager - reduce scrap costs and reduced need for visual inspection of the output quality. This is extremely beneficial for a business that is influenced by a very low unemployment rate - so that they can automate their processes and allocate their labour more effectively.