Process Improvement And Benefit Analysis In Molding Production Of Plastic Parts Of Server’s Disks

With the development of economic globalization, foundry enterprises arefacing fiercer competition. In the plastic component line, injection molding isone of the most popular manufacturing processes. The key technology points ofinjection molding are plastic mould design and the parameters of injectionmolding machine. Normally, relying on technical staff’s technical knowledge,the correct design and parameters could be got by several attempts. However,for some special products or complex structures and shapes, technical staffs areoften unable to get a better solution quickly. Besides, due to the socialdevelopment and the variety of market demands, is has became a trend for themanufacturing industry tat a company should be able to produce small quantity,and diverse products and bring up them to the market in a short response time.Enterprises have to shorten new products development cycle and standardizeproduction techniques to win the market.This paper takes N company OEM for S company’s M series server’s diskplastic bracket as the object of study. By evaluating and optimizing themanufacturing processes, in the process of sample development we found thatthe main quality problem was bad plastic shrapnel bracket. The author appliedSix Sigma DMAIC approach and set up a project team. Firstly, the key problemwas defined plastic molding Flow Chart was then analyzed. Cause and EffectMatrix was constructed. Finally, by using Failure Model and Effects Analysis,the key quality factors were identified as mold design and molding processparameters settings.This paper focuses on the use of Mold Flow analysis to find out the bestsolution for mold design, and by orthogonal experimental design method tooptimize the molding parameters of molding machine and find out the suitablequality factors and level combination. In accordance with mass productiontesting improvement results, Minitab and CPK index was used to compare thechanges before and after the improvement, to meet customer’s requirement,realize quick release of new products, stable mass production, and create profit for both customer and enterprise. For the same or similar plastic products, thisdevelopment experience could be used to improve customer satisfaction andenhance competitiveness of enterprise by saved cost，shorten development timeand improved quality.