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Six Sigma Project on Reducing Plastic Injection Molding Rejects


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  Post Number #1  
Old 18th August 2006, 10:24 PM
Vestvera

 
 
Total Posts: 3
Please Help! Six Sigma Project on Reducing Plastic Injection Molding Rejects

Recently, i just started a six sigma project on reducing plastic injection molding rejects. Any reference or example to share? Thanks
Thanks to Vestvera for your informative Post and/or Attachment!

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  Post Number #2  
Old 19th August 2006, 06:50 PM
Bev D's Avatar
Bev D

 
 
Total Posts: 3,305
Re: Six Sigma Project on Reducing Plastic Injection Molding Rejects

well, what are the defects? what is the defect rate? ow many different product types what is the defect pareto? how many different pieces of equipment? are you working on one defect type? one product type?
what is the time series of defect rates by defect type?

we need more details. this isn't a cookbook exercise.
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  Post Number #3  
Old 20th August 2006, 07:15 AM
JPSmith

 
 
Total Posts: 3
Re: Six Sigma Project on Reducing Plastic Injection Molding Rejects

And give brief definitions of defects for the non-molders here.

Is this is a school project?
  Post Number #4  
Old 20th August 2006, 07:28 AM
Vestvera

 
 
Total Posts: 3
Re: Six Sigma Project on Reducing Plastic Injection Molding Rejects

Hi, Thanks for your response. Currently my project statement is to reduce wheel assembly rejection rate from 30% to 5%. This wheel assembly process contain of the overmold process (two molding process). involving a lot of handling activities from process 1 to 2. This wheel assembly is TPE material that so soft and easily cause the defects. The current process performance in the pareto chart showed the dent and scratch were the highest defects of 10.2% and 7.3% representive. Any format and example to start off this project?

Last edited by Vestvera; 20th August 2006 at 10:44 AM.
  Post Number #5  
Old 20th August 2006, 11:15 AM
Bev D's Avatar
Bev D

 
 
Total Posts: 3,305
Re: Six Sigma Project on Reducing Plastic Injection Molding Rejects

before I respond - I must ask what training you have had on six sigma? the questions you ask are very basic, whether you are "doing a six sigma project" or have simply been tasked to improve the process.

If you are in a six sigma training program your instruction in the first week shoudl have covered your questions
  Post Number #6  
Old 21st August 2006, 04:18 AM
Vestvera

 
 
Total Posts: 3
Re: Six Sigma Project on Reducing Plastic Injection Molding Rejects

Quote:
In Reply to Parent Post by Bev D View Post

If you are in a six sigma training program your instruction in the first week shoudl have covered your questions
What i referring is the powerpoint format to start off my project. This is the purpose of the presentation to my top management. Currently take off the six sigma black belt program. Just beginning of the program and hopefully can acquired as much knowledge as can. Any powerpoint format available? Thanks
  Post Number #7  
Old 21st August 2006, 10:48 AM
Bev D's Avatar
Bev D

 
 
Total Posts: 3,305
Re: Six Sigma Project on Reducing Plastic Injection Molding Rejects

my recommendation would be to provide a Pareto-Trend of the defects currently experienced.
you might look at the last 6-12 months of data (whatever makes sense) and pareto by quantity of occurence (assuming that cost to fix is the same for each defect type - regrind? if cost isn't the same, then you might also pareto by cost for each defect type).
then take each of the top 5-10 defect types, trend the occurence rate for the same period of time as the pareto. (Do not trend cost only occurrence rate, monthly or weekly depending on volumes.) This show demonstrates whether or not the defects are stable, increasing, decreasing or if a spiek occurred and has since been corrected. it adds info to the pareto that will help with prioritization of which defects you should pursue.

I would aslo repeat this for each of the top product types - there are likely differences in some defect occurrences based on product types.

you would then select the top defect/products as the target for your project

In my handouts I use a portrait format with a tall pareto that has the trend charts positioned to the right of their pareto bar...in an overhead I show the pareto on one slide then the trend charts in pareto order on a second slide...
  Post Number #8  
Old 21st August 2006, 01:33 PM
gszekely

 
 
Total Posts: 205
Re: Six Sigma Project on Reducing Plastic Injection Molding Rejects

Try here for template.
http://www.isixsigma.com/offsite.asp.../templates.htm
I 'm on holliday, if you are intrested later, I can check for my one.
Do you need anything else than the template ?
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