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Posts Tagged ‘Manufacturing’

Question by justbecause: Manufacturing process?
What is the manufacturing process of plastic gears – in particular, nylon gears. I’ve read somewhere that its injection molding and in other articles i’ve read its milling/hobbing. Anyone know what is correct? Thank you in advance – much appreciated!

Best answer:

Answer by tadtam
injection molding. milling would be cost prohibitive

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Question by Josh S: what are some manufacturing process for HDPE?
I’ve been searching Google all day now and i can not find out some ways to manipulate HDPE into becoming a product.

I do have a feeling that it is probably blow Molding or injection Molding.

Best answer:

Answer by Rolan R
Right, you are.
Blow-molding.
Found it in wikipedia.

just a one-liner there:
http://en.wikipedia.org/wiki/Hdpe#Applications

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Question by Mike: How do I profit from an idea for an improved manufacturing process? It would dramatically increase molding.?
My idea would dramatically increase the output of injection molding machines. It is preposterously simple and requires no new technology. I need to know what I can do to profit from this. Can I patent the process and sell it? If I was to implement the idea in an injection molding company (which I do not own or work for at present), I would enjoy a significant competitive advantage for a short time. However, this idea is so simple to implement it would quickly spread throught the industry, erasing the competitive advantage.

Best answer:

Answer by Lawrence
Apply for a patent. Proceed with the work needed to prepare your patent application and obtain your patent number. You will likely need the assistance of a patent attorney and their research staff to prepare the patent application, defining the process’ description and research any references to similar art.

Then offer your patent applied for / patented process technique to industry under the terms of an NDA (non-disclosure agreement)

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Question by swarup s: I am PG in Advanced Manufacturing, which to chose?Java with mech domain@Madurai or Pro/e modelling@Blore.?
I am PG in Advanced Manufacturing Technology graduating in 2008, I have 2 career oppurtunities both in the same company.Company is a prestigious one.which option to chose?Java with mechanical domain(Design or Analysis)@Madurai or Pro/e modelling(Sheetmetal/Plastic Injection moulding)@Bengaluru.which option has a high career growth and future employment oppurtunities?

Best answer:

Answer by Shya m
java with mech domain@madurai

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Question by Mary K: Need help targeting the most rapidly growing US manufacturing sectors?
I am trying to figure out what kind of finished goods manufacturing is still done in the US? Are there any areas that are actually increasing their business?

My reason for the questions is that I work for a small injection molder (plastics) and we just lost a big customer to a mexican molder. Cheap labor, nafta, no environmental regs, etc….

Most of our customers are either hurting (like automotive industry) or appliance makers, which are also slowing down.

We offer some secondary services such as assembly, painting, printing, etc.

Just looking for help to try to find areas to target to here in the US since it seems like lots of our business is moving out of the country. Any suggestions?

Trying to keep this positive, any suggestions of areas to target or groups to join or places to look?

I know there are a lot of smart ppl that answer here on yahoo, hoping someone can give me a spark.
To answer the question about what we do…
We have from 20 to 440 T machines, so mainly smaller precision parts.

Some things we mold are:

**appliance knobs, buttons handles, bezels (painted hi- low or numbers)
**plastic water and polution filters
**electronics cases, buttons,
**automotive cases, covers, knobs, buttons, light tubes, reflectors, )
mostly under hood, part of guages in dash or inside the door frame parts)
** medical cases (we are not clean room or white room though, so not too much medical)
Consumer goods- mop assemblies, small buckets, scrapers, etx.
We do some pretty complicated precise parts and do them well. Not optics, but fairly difficult.

Best answer:

Answer by y2kgbmike
i know Alabama is booming with the automotive industry, either manufactures and suppliers

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This video is a compilation of footage shot on location by Global Sourcing Specialists (www.productgss.com) in Chinese factories. The video gives an overview of the injection molding tooling process, as well as how products are produced, assembled, and packaged. The song is “Roll it Up” by Crystal Method.
Video Rating: 3 / 5

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Injection Molds and Rotational Molds – Manufacturing For a Demanding Marketplace

The world has become very dependent upon plastic products. From household items to industry and aerospace, plastic in its many formulations has transformed modern manufacturing and created conveniences and economies unimagined in the early decades of the 20th century.

Injection Molds

The injection molding industry took hold in 1946 when James Hendry built a screw injection molding machine. But, his technology was based on an earlier invention by John Wesley Hyatt who, in 1868 injected hot celluloid into a mold to make billiard balls. Hyatt’s method used a plunger to force the material inside a mold. Hendry’s improvement was revolutionary because it eliminated the plunger and replaced it with an auger-type action that better distributed material and facilitated the use of plastic inside molds.

Today’s injection molds use much the same process and produce a wide variety of products from car panels to outdoor furniture, small toys and tools. Injection molding is ubiquitous in manufacturing and uses many different materials from polymer plastics to aluminum, copper and other metals. The plastic bottles and kitchen implements people use in everyday life are products of the injection process.

Because the metal molds are generally expensive to produce, injection molding is most economically used when thousands of pieces are being manufactured. Molds are made of hardened steel or, more recently, aluminum which is less expensive.

The Injection Process

Described very simply, molten plastic is injected into the mold under high heat and pressure. The goal is to have the molten plastic material evenly flow to all parts of the mold, creating an exact, consistent, solid plastic replica of the mold cavity. After a brief cooling cycle, the mold or tooling mechanically ejects the plastic part which then moves on through the manufacturing process. In the injection molding industry, this is a completely automated process that’s very fast and extremely efficient.

Rotational Molding

Rotational molding is yet another method of producing multiple products, most often made with a variety of plastic powders. This process is usually used in making hollow products such as traffic cones, canoes, kayaks, bicycle helmets and giant tanks used for water or chemical storage.

Like Injection molding, rotational molding had its roots in the 1940s. But it was not until the technology was more sophisticated and new polymer and plastic formulations became available that the rotational process became a mainstream manufacturing method.

Rotational Process

The two processes are quite different. Let’s consider, for example, a 300 gallon water storage tank made of polyethylene. Picture a master mold made of aluminum or steel. The plastics manufacturer pours poly resin powder into the mold that is fitted inside an oven. Once sealed, the mold is mechanically turned on at least three axes, moving much like a gyroscope. At the same time, the oven is raised to an appropriate temperature and the polymer – or other material – tumbles inside and slowly coats the inner walls of the mold, melting as it rotates.

Once the optimal temperature is reached, the mold is cooled. As the temperature of the mold itself falls, the product on the inside shrinks away from the inner walls and is easily removed. This is not always the case with injection molds that are often more difficult to successfully remove. The shrinking action of rotational molding is particularly desirable when the product is very large and awkward to handle.

Rotational molding is also more economical for some products because less material is used. In addition, the polymer that is left over from one mold can be used in another. The method itself is more streamlined than injection molding, which requires more interlocking parts.

Materials Improve and Expand

Most products made with the rotational molding method are from the polyethylene family. Other materials include nylons, polypropylene and PVC plastics. Some manufacturers have developed formulas that integrate the use of natural materials such as sand and chips of stone to make products.

Plastic and resin products are now an integral part of everyday life and supply us with items as tiny as paper clips and as big as storage tanks. As the industry developed, so too has environmental awareness about the safety and use of these petrochemical-based products. Today, materials can meet the specifications of FDA requirements, and other health and safety related regulations. Producers are also cooperating to create products that can be recycled.

Plastic Machinery Manufacturing Industry in China's export situation analysis

China’s plastics machinery manufacturing industry 50 years from the 20th century produced the first product since, after almost half a century, especially the rapid development since the reform and opening up, and now have built a full range, the main technical and economic indices, or reached the international advanced level, supporting internationalized production gradually specialized, complete with large-scale industrial system, the product basically meet the domestic demand, rapid increase in export capacity. I. Current Situation of China plastic machinery manufacturing industry currently engaged in manufacturing plastics machinery and related enterprises, about 600 units, of which plastic molding equipment can provide about 250. China’s plastics machinery industry has a considerable scale, at present, China’s leading plastic machinery production capacity more than 10 million sets, which, out of more than 8,000 sets of equipment, 30,000 sets of injection molding machines, blow molding equipment, more than 3,000 sets of plastic machinery annual turnover of 8.0 billion ~ 10 billion yuan. Plastic products from the market analysis, combined with our existing plastic machinery production capacity into full play, from 2001 to 2010, China’s domestic market capacity of plastic machinery products the average annual growth of about 6%. 2000, 2005 were 80 billion yuan, 11 billion yuan, is expected to reach 14.5 billion by 2010. With the improvement in the quality of our products and variety increase, plastic machinery products in the domestic market share will increase as expected were 70%, 75% and 80%; plastic machinery products were 5.6 billion total industrial output value , 8.25 billion yuan and 11.6 billion yuan. With the increase of China’s exports in 2010, China’s industrial output value of plastic machinery products reached 140 billion yuan, 2.33 times in 2000, the annual average growth rate of about 9% in 2001 and 2005 annual growth rate of 10% 2006 to 2010 annual growth rate of 8%. Plastic machinery products from the quantitative analysis, 2000, 2005, were 5.5 million, 7.5 million units in 2010 to 10 million units, of which about 35% of the injection molding machine, extruder, 25%, about Blow Molding Machine 5%, 35% of other presses. Second, China’s exports of plastic machinery manufacturing industry of plastic equipment for general use in addition to meet the domestic demand, equipment exports also increased year by year. 3 years, China’s plastics machinery exports in the period of fastest growth in history. Long, exports have been about 50 million U.S. dollars in 1998, more than 100 million U.S. dollars in 2001 to 238 million U.S. dollars, up 31.09 percent over 2000. Experts believe that the future of China’s exports of plastic machinery injection molding machine will be based. From the quantitative analysis of the export is expected to share all kinds of aircraft were: 60.4% of injection molding machines, extruders 6.8%, 11.7% blow molding machine, the other presses 21.1%. From the amount of plastic machinery products export point of view, 74.1% of injection molding machines, extruders, 8.1%, blow molding machine, 8%, other plastic machinery products accounted for 9.8%. 3, plastic and rubber mold export Moreover, the rise of China Mould exports momentum. In 2002, China exported 19,500 tons mold, to 252 million U.S. dollars. Among them, the plastic or rubber mold to 467,800 units, about 172 million U.S. dollars, accounting for 68.3% of total exports of the mold. Major sources of exports of plastic molds to Guangdong, Zhejiang, Shanghai and Fujian Province, accounting for 57% of exports of the country mold, 13.9%, 11% and 5.2%. The main export markets are Hong Kong, China, Japan, China Taiwan Province, United States and Singapore, followed by Vietnam, Thailand, Malaysia, South Korea, India, Indonesia and Mexico. Although the origin of China’s plastic mold all over the country but mainly concentrated in the southeast coastal provinces and cities, especially in the Pearl River Delta and Yangtze River Delta area where the concentration. By provinces, the Guangdong Province and Zhejiang Province, the most developed. The two provinces produce plastic mold mold production accounts for about 2 / 3. , Dongguan, Shenzhen, Shunde, Guangdong Province, the most advanced plastic mold parts; and Ningbo, Taizhou, Zhejiang Province, is the most advanced producer. Plastic injection mold plastic mold of the key products, primarily serves the automotive, motorcycle and electrical industries.

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Custom Injection Moliding and the Lean Manufacturing Process

Custom injection molding has always been a fast moving, chaotic, and challenging business. It also has a high potential for profit, even today, despite the international competition and tight margins. You want to succeed, you see the possibilities, but the global pricing and high expenses make it very difficult.

Plastic injection molders are in the almost ideal business to benefit from the lean manufacturing process. If you embrace the entire concept and do not cherry pick the parts that are quick and easy, you will most certainly experience improvements in your operation.

The lean manufacturing process is an integrated approach to reducing waste. It could be time or material or anything else; waste is waste and waste equals money in business. It requires a shift in thinking to approach efficiency from this vantage point, rather than always striving to do more, do it faster, do it better.

Six Sigma

Implementing six sigma requires that management is dedicated to making it work in the long run. Employees are often cynical toward new programs because, in the past, many programs amounted to little more than slogans and banners.

Using a six sigma consulting firm is a good idea, once you have educated yourself in the basic principles. The time and expense of hiring an outside consultant will pay off handsomely over time. If you have the personnel to mange your six sigma implementation in-house that is even better; though they will certainly need some additional training.

5S

5S training will give you a huge boost in your lean manufacturing process. This is because the results are so immediate and visible. Everyone likes having the tools they need, the materials in the proper place with labels, and a general atmosphere of everything in it’s place.

It is relatively easy to get your employees to go along with a 5S program. Within a week you will see changes in your production area and the attitude of everyone. Find the key people, train them, give them the authority and communicate with the entire workforce in order to avoid grumbling and confusion.

Kaizen

When you conduct a kaizen blitz, or event, you pick an area or a process and focus exclusively on it. This is a great way to make progress and get people involved because it is by nature short and intense. It is a bit like cleaning up you kitchen before your mother-in-law comes for a visit! You hyper-focus on one area after another until the whole is done.

One drawback though with a kaizen blitz is that it can be mistakenly understood to be the entire process. It is just a component and it should be regarded as such. If it becomes the program, you will not really change the culture or become much more efficient in your operation.

How to get going

It is a good idea to talk to successful shop owners who have benefited from the lean manufacturing process. You will find them enthusiastic and quite willing to open up, for the most part. You should also read and gather information so you can make wise decisions rather than totally rely on the opinion of a consultant. In the end, you will certainly need outside help, but you also need a thorough understanding of the process yourself.

Randy Hough
Plastic Injection Mold Maker
http://whatisleanmanufacturing.com

“You know Dad, I’ve been thinkin’, one is a lot more than zero!” my son, Thomas, age 5.

More Plastic Injection Articles

Question by Victoria L: Find Sova Plastic Products Manufacturing comapny Plastic blow molding injection molding?

Best answer:

Answer by jdkilp
http://sova-tech.com

42450 Executive Dr
Canton, MI , 48188-2259
Phone: 734-844-6707
FAX: 734-844-6727
CELL: (734) 730-2497
SOVA-TEC@SOVA-TECH.COM

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