Overview of injection molding workshop management
Injection molding is a 24-hour continuous operation, involving plastic raw materials, injection molds, injection molding machines, peripheral equipment, fixtures, sprays, toners, packaging materials and auxiliary materials, etc., and there are many positions and complex division of labor. How to make injection molding The production and operation of the workshop are smooth, achieving "high quality, high efficiency and low consumption"?
It is the goal that every injection manager expects to achieve. The quality of the injection workshop management directly affects the injection molding production efficiency, defect rate, material consumption, manpower, delivery time and production cost. Injection molding production mainly lies in control and management. Different injection managers have different ideas, management styles and working methods, and the benefits they bring to the enterprise are also quite different, even quite different...
The injection molding department is the "leading" department of each enterprise. If the management of the injection molding department is not done well, it will affect the operation of all departments of the enterprise, causing the quality/delivery time to fail to meet customer requirements and the competitiveness of the enterprise.
The management of the injection workshop mainly includes: the management of raw materials/toner/nozzle materials, the management of the scrap room, the management of the batching room, the use and management of injection molding machines, the use and management of injection molds, the use and management of tooling and fixtures, and the staff Training and management, safety production management, rubber parts quality management, auxiliary material management, operation process establishment, rules and regulations/position responsibilities formulation, model/document management, etc.
1. Scientific and reasonable staffing
The injection molding department has a variety of tasks, and a scientific and reasonable staffing is required to achieve a reasonable division of labor and clear job responsibilities, and achieve the status of "everything is in charge and everyone is in charge". Therefore, the injection molding department needs to have a good organizational structure, reasonably divide the labor and work out the job responsibilities of each post.
two. Management of batching room
1. Formulate the management system of the batching room and the batching work guidelines;
2. The raw materials, toners, and mixers in the batching room should be placed in different areas;
3. The raw materials (water-containing materials) should be classified and placed and marked;
4. The toner should be placed on the toner rack and must be well marked (toner name, toner number);
5. The mixer should be numbered/identified, and the use, cleaning and maintenance of the mixer should be done well;
6. Equipped with supplies for cleaning up the mixer (air gun, fire water, rags);
7. The prepared materials need to be sealed or tied with a bag sealing machine, and labeled with identification paper (indicating: raw materials, toner number, use machine, batching date, product name/code, batching personnel, etc.;
8. Use the ingredient Kanban and ingredient notice, and do a good job of recording ingredients;
9.White/light colored materials need to be mixed with a special mixer and keep the environment clean;
10. Train the ingredients personnel on business knowledge, job responsibilities and management systems;
3. Management of the scrap room
1. Formulate the management system of the scrap room and guidelines for scrap work.
2. The nozzle materials in the scrap room need to be classified/zoned.
3. The crushers need to be separated by partitions to prevent the scraps from splashing out and causing interference.
4. After the crushed material bag, it must be sealed in time and labeled with identification paper (indicating: raw material name, color, toner number, scrap date and scraper, etc.
5. The crusher needs to be numbered/identified, and the use, lubrication and maintenance of the crusher should be done well.
6.Regularly check/tighten the fixing screws of the crusher blade.
7. The transparent/white/light-colored nozzle material needs to be crushed by a fixed machine (it is better to separate the crushing material room).
8.When changing the nozzle material of different materials to crush, it is necessary to thoroughly clean the crusher and blades and keep the environment clean.
9. Do a good job of labor protection (wear earplugs, masks, eye masks) and safety production management for scrapers.
10. Do a good job of business training, job responsibilities training and management system training for scrapers.
4. On-site management of injection workshop
1. Do a good job in the planning and regional division of the injection molding workshop, and reasonably specify the placement area of the machine, peripheral equipment, raw materials, molds, packaging materials, qualified products, defective products, nozzle materials and tools and tools, and clearly identify them.
2. The working status of the injection molding machine needs to hang a "status card".
3. "5S" management work at the production site of the injection workshop.
4. "Emergency" production needs to specify the output of a single shift, and hang the emergency card.
5. Draw the "feeding line" in the drying barrel and specify the feeding time.
6. Do a good job in the use of raw materials, the control of the nozzle material of the machine position and the inspection of the amount of waste in the nozzle material.
7. Do a good job in patrol inspection during the production process, and increase the implementation of various rules and regulations (move around in time management) 8. Reasonably arrange machine personnel, and strengthen on-site labor discipline inspection/supervision.
8. Do a good job in the manpower arrangement and handover of the meal time of the injection molding department.
9. Do a good job in the cleaning, lubrication, maintenance and handling of abnormal problems of the machine/mold.
10. Follow-up and exception handling of product quality and production quantity.
11. Inspection and control of post-processing methods and packaging methods of rubber parts.
12. Do a good job in the inspection of safety production and the elimination of potential safety hazards.
13. Do a good job in the inspection, recycling and cleaning of machine position templates, process cards, operation instructions and related materials.
14. Strengthen the inspection and supervision of the filling status of various reports and kanban content.
5. Management of raw materials/color powder/nozzle materials
1. Packaging, labeling and classification of raw materials/color powder/nozzle materials.
2. Requisition records of raw materials/toner/nozzle materials.
3. The unpacked raw materials / toner / nozzle materials should be sealed in time.
4. Training on plastic properties and material identification methods.
5. Formulate regulations on the proportion of nozzle materials added.
6. Formulate toner storage (toner rack) and usage regulations.
7. Formulate material consumption indicators and requirements for replenishment applications.
8. Regularly check the raw materials / toner / nozzle materials to prevent the loss of materials.
6. Use and management of peripheral equipment
The peripheral equipment used in injection molding production mainly includes: mold temperature controller, frequency converter, manipulator, automatic suction machine, machine edge crusher, container, drying barrel (dryer), etc., all peripheral equipment should be done well Use/maintenance/management work can ensure the normal operation of injection molding production. The main work contents are as follows:
Peripheral equipment should be numbered, identified, positioned, and placed in partitions.
Do a good job in the use, maintenance and maintenance of peripheral equipment.
Post "Operation Guidelines" on peripheral equipment.
Formulate regulations on the safe operation and use of peripheral equipment.
Do a good job in the operation/use training of peripheral equipment.
If the peripheral equipment fails and cannot be used, the "status card" needs to be hung up-equipment failure, waiting for repair.
Establish a list of peripheral equipment (name, specification, quantity).
7. Use and management of fixtures
Tooling fixtures are indispensable tools in the injection molding processing industry. They mainly include fixtures for correcting product deformation, plastic parts shaping fixtures, plastic parts piercing/nozzle processing fixtures, and drilling fixtures. In order to ensure the quality of plastic parts processing, it must To manage all fixtures (fixtures), the main work content is as follows:
Number, identify and classify tooling fixtures.
Regular maintenance, inspection and maintenance of fixtures.
Formulate "Operation Guidelines" for fixtures.
Do a good job in the use/operation training of fixtures.
Safety operation/use management regulations of tooling fixtures (such as: quantity, sequence, time, purpose, positioning, etc.).
File the fixtures, make fixture racks, position them, and do a good job of receiving/recording/managing.
8. Use and management of injection mold
The injection mold is an important tool for injection molding. The condition of the mold directly affects the quality of the product, production efficiency, material consumption, machine position and manpower and other indicators. If you want to make production smoothly, you must do a good job in the use, maintenance and maintenance of the injection mold. And management work, its main management work content is as follows:
The identification (name and number) of the mold should be clear (preferably identified by color).
Do a good job in mold testing, formulate mold acceptance standards, and control mold quality.
Formulate rules for the use, maintenance and maintenance of molds (see "Injection Mold Structure, Use and Maintenance" textbook).
Reasonably set mold opening and closing parameters, low pressure protection and mold clamping force.
Establish mold files, do a good job of mold dust prevention, rust prevention, and registration management of in and out of the factory.
Special structure molds should specify their use requirements and sequence of actions (posting signs).
Use suitable die tools (make die special carts).
The mold needs to be placed on the mold rack or card board.
Make a mold list (list) or place an area billboard.
nine. Use and management of spray
The sprays used in injection molding production mainly include: release agent, rust inhibitor, thimble oil, glue stain remover, mold cleaning agent, etc., all sprays should be used and managed well in order to give full play to their due The main functions are as follows:
The type, performance and purpose of the spray should be specified.
Do a good job of training the spray dosage, operation method and scope of use.
The spray must be placed in a designated place (ventilation, ambient temperature, fire prevention, etc.).
Formulate spray requisition records and empty bottle recycling management regulations (for details, please refer to the content in the attached page).
10. Safety production management of injection molding workshop
1. Formulate the "Safety Code for Employees of the Injection Molding Department" and "Safety Code for Workers in the Injection Mold"
2. Formulate regulations on the safe use of injection molding machines, crushers, manipulators, peripheral equipment, fixtures, molds, knives, fans, cranes, pumps, guns, and sprays.
3. Sign the "Safety Production Responsibility Letter" and implement the safety production responsibility system of "who is in charge, who is responsible".
4. Adhere to the policy of "safety first, prevention first", and strengthen the education and publicity work of safe production (posting safety slogans).
5. Make safety signs, strengthen the implementation of safety production inspections and safety production management systems, and eliminate potential safety hazards.
6. Do a good job in the training of safety production knowledge and conduct examinations.
7. Do a good job of fire prevention in the injection molding workshop and ensure that the safe passage is unblocked.
8. Post the safe fire escape diagram in the injection molding workshop and do a good job in the coordination/inspection and management of fire fighting equipment (for details, see the textbook "Safety Production Management in Injection Workshop").
11. Urgent production management
Make the machine arrangement requirements for "urgent" products.
Strengthen the use/maintenance of "urgent parts" molds (compression molds are strictly prohibited).
Make preparations for "urgent" production in advance.
Strengthen the quality control in the production process of "urgent parts".
Formulate regulations for emergency handling of molds, machines, and quality abnormalities in the production process of "urgent parts".
5. The "urgent card" is hung on the plane, and the output per hour or single shift is specified.
Do a good job in the identification, storage and management (zoning) of "urgent" products.
5. The production of "urgent items" should give priority to the arrangement of skilled craftsmen, and implement rotation start.
Take effective measures to shorten the injection cycle time to increase the output of urgent parts.
Do a good job in inspections and shifts in the production process of urgent items.
12. Management of tools/accessories
Do a good job of recording the use of tools/accessories.
Implement the tool user responsibility system (loss compensation).
Tools/accessories need to be counted regularly to find differences in time.
Formulate management regulations for the transfer of tools/accessories.
Make tool/accessory storage cabinet (locked).
Consumables need to be "traded in" and checked///confirm/i/ied.
13. Management of templates/documents
Do a good job in the classification, identification and storage of templates/documents.
Do a good job of recording the use of templates/documents (injection molding process cards, work instructions, reports).
List the template/document list (list).
Do a good job in issuing/recycling samples/documents.
Formulate management regulations for templates/documents (it is recommended to set up special personnel for management).
14. Management of upper and lower mold tools and sleeves
The upper mold tools should be configured in groups, and the registration system should be implemented to prevent loss. Otherwise, the work efficiency of the upper and lower molds will be affected, and the production time will be delayed; the upper mold tools should be in place at one time, and a special vehicle for the upper and lower mold tools should be made to reduce the need for tools. time.
If the upper mold technician does not properly control the strength of the punching screw, the length of the sleeve is too long or the force is too strong, which will cause serious slippage of the screw holes in the front and rear templates of the injection molding machine, which will cause difficulty in mold installation and potential safety inspections. Therefore. , The length of the sleeve needs to be restricted and managed, and sleeves of different lengths should be used reasonably according to the size of the size of the screw.
M12, M14 screws, suitable for L=25～30CM
M16 screw, suitable for L=30～35CM
M18 screw, suitable for L=35～40CM
M20 screw, suitable for L=40～45CM
M24 screw, suitable for L=45～50CM
15. Kanban management of injection molding workshop
The role of Kanban management:
A: Save time, clear at a glance.
B: Easy to search and improve efficiency.
C: Grasp the trend and discover problems in time.
D: Making production information public, reducing work forgetting.
E: Control the waste caused by overproduction.
F. Visual management tools for easy follow-up.
(1) Kanban for injection molding production plan
Machine number
D
Mold number
raw material
colour
quantity of order
Delivery
Daily output
Production Date
Date of completion
Function: Let relevant personnel know the production plan in time to follow up the production schedule.
(2) Injection molding production progress (documentary) Kanban
Machine number
Order number
Production name
Plastic part name
quantity of order
Delivery
Today's production
Cumulative production
Owed
Remarks
Keep abreast of the production progress and the completion of production tasks.
(3) Monthly production efficiency kanban
Function: To understand the production efficiency trend and process control status of this month.
(4) Kanban for the monthly pass rate of plastic parts
Function: To understand the quality trend of injection molding this month, in order to analyze the reasons.
(5) Daily ingredients Kanban
Function: Convenient for batching and prevent the wrong toner, wrong material or multiple material from being used.
(6) Kanban board of injection molding department
The role of the machine board:
A. Let personnel involved in production know the production arrangements and production requirements of each machine in time.
B. Keep abreast of the production status of each machine and each shift (such as: quantity, quality, failure, etc.).
C. Let every employee care about the production status and control the production progress.
D. Prevent the occurrence of short-form dropping or over-order production.
E. Prevent the relevant personnel from distributing too much material or feeding the wrong material/feeding the wrong material.
F. There is a smooth development of crew arrangements, production follow-up and management.
G. It is convenient for new employees to be familiar with the production status and management personnel, and find relevant personnel to deal with problems in time.
H. It is convenient to prepare enough to transfer the mold in advance.
Do a good job of filling in the "camera board".
(7) Injection mold board
(8) Kanban of good and bad plastic parts
(9) Kanban of nozzle material sample
(10) Kanban board for entry and exit of nozzle materials
(11) Plastic Parts Quality Control Kanban
(12) Kanban for mold change plan
(13) Production record kanban
16. Quantitative management of injection molding production
The role of quantitative management:
A. Use data to speak with strong objectivity.
B. Work performance is quantified and it is easy to realize scientific management.
C. Conducive to enhancing the sense of responsibility of staff in various positions.
D. Can stimulate the enthusiasm of employees.
E. It can be compared with the past and scientifically formulated new work goals.
F. It is helpful to analyze the cause of the problem and propose improvement measures.
1. Injection molding production efficiency (≥90%)
Production equivalent time
Production efficiency =————————×100%
Actual production switchboard
This indicator evaluates the quality of production process control and work efficiency, reflecting the technical level and the stability of production.
2. Raw material usage rate (≥97%)
Total weight of warehousing plastic parts
Raw material usage rate=————————×100%
Total weight of raw materials used in production
This indicator assesses the loss of raw materials in injection molding production and reflects the quality of the work of each position and the control of raw materials.
3. Batch qualification rate of rubber parts (≥98%)
IPQC inspection OK batch quantity
Batch qualification rate of rubber parts =————————————×100%
Total number of batches submitted for inspection by injection molding department
This indicator assesses the mold quality and the defective rate of rubber parts, reflecting the work quality, technical management level and product quality control status of personnel in various departments.
4. Machine utilization rate (utilization rate) (≥86%)
Actual production time of injection molding machine
Machine utilization rate=——————————×100%
Theoretically should be produced
This indicator evaluates the downtime of the injection molding machine, and reflects the quality of the machine/mold maintenance work and whether the management work is in place.
5. On-time storage rate of injection molded parts (≥98.5%)
Number of injection molded parts
On-time warehousing rate of injection molded parts =——————————×100%
Total production schedule
This indicator assesses the injection molding production schedule, work quality, work efficiency and punctuality of plastic parts warehousing, and reflects the status of production arrangements and production efficiency follow-up efforts.
6. Mold damage rate (≤1%)
Number of damaged molds in production
Mold damage rate =——————————×100%
Total number of molds put into production
This indicator assesses whether the mold use/maintenance work is in place, and reflects the work quality, technical level, and mold use/maintenance awareness of relevant personnel.
7. Annual effective production time per capita (≥2800 hours/person.year)
Annual total production equivalent time
Annual effective production time per capita=——————————
Annual average number of people
This indicator assesses the control status of the machine position in the injection molding workshop and reflects the improvement effect of the mold and the improvement ability of the injection molding IE.
8. Delay in delivery rate (≤0.5%)
Number of delayed delivery batches
Delay in delivery rate =——————————×100%
Total number of delivered batches
This indicator assesses the number of delays in the delivery of plastic parts, reflecting the coordination of the work of various departments, the follow-up effect of the production schedule, and the overall operation and management of the injection molding department.
10.Up and down time (hour/set)
Large model: 1.5 hours Middle model: 1.0 hour Small model: 45 minutes
This indicator assesses the work quality and efficiency of the molder/technical personnel, and reflects whether the preparation work before the mold is in place and the technical level of the adjustment personnel.
11. Safety accidents (0 times)
This indicator assesses the level of safety production awareness of personnel in each position, and the status of safety production training/on-site safety production management of employees at all levels by the injection molding department, reflecting the importance and control of safety inspection production management by the responsible department.
Seventeen. documents and materials required for the injection molding department
1. "Operation Instructions" for injection molding machine employees.
2. Operating instructions for injection molding machines.
3. Quality standards for injection molded parts.
4. Standard injection molding process conditions.
5. Change record sheet of injection molding process conditions.
6. Injection molding machine/mold maintenance record sheet.
7. Quality control personnel rubber parts inspection record table.
8. Machine position production record sheet.
9. Machine location model (such as: confirmation OK sign, test board, color board, defect limit model, problem model, processed part model, etc.).
10. Station board and status card (including emergency card).