Total quality process control for injection molding:
Gespeichert in:
| 1. Verfasser: | |
|---|---|
| Format: | Buch |
| Sprache: | English |
| Veröffentlicht: |
Hoboken, NJ
Wiley
2010
|
| Ausgabe: | 2. ed. |
| Schriftenreihe: | Wiley series in plastics engineering and technology
|
| Schlagworte: | |
| Online-Zugang: | Inhaltsverzeichnis |
| Beschreibung: | XVIII, 746 S. Ill., graph. Darst. |
| ISBN: | 9780470229637 0470229632 |
Internformat
MARC
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| 100 | 1 | |a Gordon, M. Joseph |e Verfasser |4 aut | |
| 245 | 1 | 0 | |a Total quality process control for injection molding |c M. Joseph Gordon |
| 250 | |a 2. ed. | ||
| 264 | 1 | |a Hoboken, NJ |b Wiley |c 2010 | |
| 300 | |a XVIII, 746 S. |b Ill., graph. Darst. | ||
| 336 | |b txt |2 rdacontent | ||
| 337 | |b n |2 rdamedia | ||
| 338 | |b nc |2 rdacarrier | ||
| 490 | 0 | |a Wiley series in plastics engineering and technology | |
| 650 | 4 | |a Injection molding of plastics / Quality control | |
| 650 | 4 | |a Injection molding of plastics |x Quality control | |
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Datensatz im Suchindex
| _version_ | 1804139344808640512 |
|---|---|
| adam_text | Contents
Preface
xvii
1. Total
Quality Process Control
1
ISO
9001 / 2
Documentation
/ 5
Establishing Process Ownership
/ 5
Ideas and Methods
/ 13
2.
Implementing Total Quality Process Control (TQPC)
15
Quality Improvement Plan
/17
Statistical Process Control
(SPC)
/ 19
Controlling the Process
/19
Cp the Control of Operations
/ 20
Cpk-Centered Process Control
/ 23
Establishing Company Quality Objectives
/ 25
Customer Quality
/ 27
3.
Managing for Success, Commitment to Quality
28
Objectives for Managing a Quality System
/ 28
Proactive Preventive Action
/ 29
Total Quality Process Control
/ 30
Attitude
/ 30
VI
CONTENTS
Control of Change
/ 32
Improvement with Control of Change
/ 33
Quality Decisions
/ 34
Principles for Quality Systems Engineering
/ 34
Objectives for Managing a Quality System
/ 34
Customer-Supplier Quality Agreements
/ 36
Captive Part Quality
/ 36
Product Quality Determination
/ 36
Parts to Print
/ 36
Form, Fit, and Function
(FFF)
/ 39
Product Requirements
/ 40
Existing Mold Considerations
/ 40
Establishment of Responsibility
/ 42
Department TQPC Responsibility
/ 44
Program Development
/ 45
Estimated Piece Part Price
/ 46
Multifunctionality
/ 48
Assembly and Decorating
/ 48
Manufacturing Capability
/ 48
Computer-Integrated Manufacture
(СІМ)
/ 49
Tracking Manufacture
/ 52
RFID
/ 52
EDI
/ 52
Just-In-Time
/ 53
Control of Operations
/ 53
Process Control
/ 54
Control Charting
/ 54
International Organization for Standardization (ISO) Accreditation
/ 57
Program Monitoring
—
Communication
/ 57
Communicating Quality in Business
/ 58
Communications
/ 58
Surveys
/ 59
Quality Function Deployment (QFD)
/ 61
QFD in Operation
/ 62
Customer Feedback
/ 63
Critical to Quality (CTQ)
/ 66
Building on TQPC, Product Manufacture
/ 67
Checklists
/ 67
Quality Circles
/ 69
CONTENTS
VU
Fishbone Analysis
/ 69
Failure Mode and Effects Analysis
/ 70
Types of FMEAs
/ 71
FMEA Timing
/ 73
Implementing an FMEA
/ 74
FMEA Development
/ 74
4.
Customer Satisfaction
79
Manufacturing and Supplier Input
/ 80
Vendor Selection
/ 80
Vendor Survey
/81
Customer and Supplier Agreements
/ 82
Vendor Clinics
/ 83
Product Requirements
/ 83
Product Preproduction Review
/ 84
Contract Checklist
/ 84
5.
Organization Responsibilities
86
Quality Operations
/ 89
Quality Uniformity
/ 91
Compliance Audits
/ 91
Six Sigma Introduction
/ 92
Procedure
/ 93
Quality Problems
/ 94
TQPC Management Operations
/ 96
Preventive Action
/ 103
6.
Establishing the Limits for Quality Control
105
Preproduction Product Analysis
/ 108
Taguchi Methods
/ 108
Prototyping
/ 109
Mold Limits /111
Material Selection
/114
Calculation of Plastic Part Cost
/ 115
Case Study of Product Cost Analysis
/116
Estimating Part Cycle Time
/116
Mold Part Cavity Estimation
/118
Mold Size Considerations
/119
Injection Molding Machine Selection
/ 119
VIH
CONTENTS
Melt Generation
/ 121
Molding Machine Screw-type Considerations
/ 122
Machine Hourly Rate
/ 122
Machine Setup Charges
/ 124
Calculating Product Manufacturing Cost
/ 126
Material Supplier Limits
/ 129
Establishing Manufacturing Limits
/ 129
Auxiliary Equipment
/ 131
In-Process Inspection
/ 131
Establishing Total Quality Process Control
/ 132
Acceptable Quality Limits
/ 134
7.
Material Selection and Handling
135
Thermosets
/ 136
Thermoplastics
/ 137
Amorphous Plastics
/137
Crystalline Plastics
/ 137
Classifying the Polymers
/ 138
Product Certification
/ 138
Material Specification
/ 140
Product Variable Specification
/ 143
Incoming Material Testing
/ 143
Material Testing Equipment
/144
Types of Tests
/ 144
Analyzing the Tests
/ 145
Differential Scanning Calorimeter
/ 146
Thermogravimetric
/ 149
Gel Chromatography
/ 150
Test Methods
/ 153
Material Safety Data Sheets
/ 163
Record Accuracy
/ 163
Bar Coding: An Aid in Total Quality Process Control
/ 164
Regrind Control
/ 165
Material Handling and Storage
/ 165
Regrind Usage
/ 166
Processing Aids
/ 168
8.
The Mold
169
Computer-Integrated Manufacture
/ 170
Pre-mold Design Checklist
/172
CONTENTS
ІХ
Part Design / 172
Material
Selection /
173
Shrinkage
/ 173
Molding Machine Capability
/173
Strength of Materials for the Mold
/ 174
Fluid Flow in Mold
/ 174
Venting the Mold
/ 175
Heat Transfer
/ 175
Thermal Conductivity
/ 176
Thermal Expansion of the Mold
/ 176
Coefficients of Friction
/ 176
Abrasion Resistance
/ 176
Corrosion Resistance
/ 177
Ejector System
/ 177
Draft and Shut-off
/ 177
Part Drawings and Dimensional Stackup
/ 179
Mold Setup
/ 180
Secondary Operations
/ 180
Maintenance/Repair/Operation
/180
Methods of Construction
/ 181
Tooling
/ 182
Processing
/182
Reviewing Existing Tooling
/182
Part Cost and Cavity Optimization
/ 183
Prototype Tooling
/ 183
Production Tooling
/184
Pricing the Tool
/ 190
Tool Scheduling
/ 192
Tool Steel Selection
/ 192
Selecting Materials for the Mold
/ 195
Corrosion and Abrasion Resistance
/ 195
Thermal Conductivity
/ 196
Cavity Forming and Finishing
/198
Electric Discharge Machining
/ 199
Polishing
/ 203
Texturing
/ 203
Cavity Selection
/ 206
Part Layout
/ 206
Cavity Selection Based on Molding Machine Size
/ 208
Mold Cavity Layout
/ 210
CONTENTS
Runner Systems /212
Cavity Runner
Layout / 212
Runner System Design / 212
Gating the Part
/ 215
Material
Shrinkage
/ 216
Gate
Location
/217
Gate
Terminology
/ 217
Gate
Types
/ 220
Gate
Control of Weld Lines
/ 223
Sprues and Nozzles
/ 226
Sprue Pullers
/ 226
Sprue Bushing and Nozzle Seating
/ 226
Parting Lines
/ 228
Cavity Parting Line Location
/ 228
Complex Parting Line
/ 228
Side Core Pulls
/ 230
Side-Action Core Pull
/ 230
Delayed Side-Action Core Pull
/ 231
Slide Retainers
/ 232
Wedge Action Core Pull
/ 233
Core Selection
/ 234
Collapsible Cores
/ 234
Unscrewing Cores
/ 234
Part Ejection
/ 235
Positive Early Ejector Return
/ 237
Accelerated Ejectors
/ 237
Venting the Cavity
/ 237
Cavity Shutoff
/ 242
Cavity Considerations
/ 242
Passive Vents
/ 243
Porous Metal Vents
/ 244
Core Venting
/ 244
Positive Cavity Venting
/ 245
Blowback System
/ 245
Temperature Control
/ 245
Insulating the Mold for Temperature Control
/ 245
Mold Temperature Control
/ 246
Cavity Temperature Control
/ 250
CONTENTS
ХІ
Cooling Systems
/ 251
Cooling
System Layout / 251
Core Cooling
/ 252
Coolant Channel Seals
/ 255
Mold Cooling Line Connections
/257
Mold Connection Types
/ 257
Cooling Time
/ 258
Mold Shrinkage
/ 259
Post-Mold Shrinkage
/ 261
Calculating and Estimating Part Shrinkage
/ 264
Determining Cavity Dimensions
/ 267
Hot-Runner Molds
/ 271
Processing for Hot-Runner Molds
/ 272
Mold Maintenance
/ 278
9.
Manufacturing Equipment
285
Machinery Selection
/ 285
Process Control
/ 286
Electric Injection Molding Machines
/ 287
Injection Molding Machine Nomenclature and Operation
/ 288
Reciprocating Screw Injection Molding Machine
/ 289
Injection Molding Cycle Operations
/ 290
Machine Selection for the Molding Cycle
/ 291
Resin Melt Shot Capacity
/ 291
Machine Melt Plasticizing Capability
/ 292
Injection Rate and Pressure
/ 293
Packing Pressure
/ 294
Back Pressure
/ 294
Time Variables and Controls
/ 295
Injection Molding Cycle
/ 295
The Injection Molding Machine
/ 297
The Barrel and Screw Assembly
/ 298
The Reciprocating Screw
/ 299
Nonreturn Valves
/ 305
Barrel Adaptor
/ 307
Screw Tip
/ 307
Nozzles
/ 309
Selecting Barrel Heater Conditions
/ 311
Pyrometer
/ 312
ХИ
CONTENTS
Thermocouples
/ 312
Mold Fit and Support
/ 313
Machine and Mold Clamping Systems
/ 313
Hydraulic Clamp
/313
Toggle Clamp
/ 315
Vented-Barrel Machines
/ 317
Maintenance of Machinery
/321
Preventive Maintenance
/321
Maintenance Checklist
/ 324
10.
Auxiliary Equipment
326
Material Feeders and Blenders
/ 327
Automatic System
/ 328
Central Systems
/ 329
Material Feed to the Injection Molding Machine
/ 331
Material Blending at the Hopper
/ 332
Blending Quality Checks
/ 333
Color Concentrate Blending
/ 333
Regrind Usage
/ 334
Material Drying
/ 334
Material Drying Systems
/ 335
Dryer Analysis
/ 337
Material Drying
/ 339
Dryer Bed Analysis
/ 340
Desiccant Bed Analysis
/ 343
Dryer Problem Checklist
/ 345
Dielectric Closed-loop Moisture Analysis
/ 346
Microwave Dryers
/ 346
Plant Equipment Cooling Systems
/ 346
Chiller Systems
/ 346
Mold Temperature Controllers
/ 350
Chiller Types
/ 351
Mold Heaters
/ 352
Temperature Setting
/ 352
Maintenance Checks
/ 353
Granulators
or Grinders
/ 355
Granulator
Selection
/ 357
Press-Side
Granulator / 358
CONTENTS
ХІІІ
Central Granulator / 359
Granulator Problems
and Maintenance
/ 359
Part Removal, Conveyor
Systems, and Robots / 360
Conveyor and
Part Separator Systems / 362
Robot
Part Handling
/ 365
Quality Inspection Equipment
/ 366
Quick Mold Change
/ 369
QMC Requirements
/ 369
Key Factors
/ 370
Implementing QMC
/ 370
11.
Processing
378
Production Startup for Process Control
/ 378
Acceptable Quality Level Limits
/ 379
Networking Production
/ 382
The Injection Molding Process
/ 383
Mold Startup Procedure
/ 384
Monitoring Mold Setup and Startup Procedures
/ 385
Setup Operator Responsibilities
/ 385
Injection Molding Startup
/ 389
Setting the Cycle
/ 392
Startup Procedure
/ 392
Shut-Down Procedure
/ 397
Other Molding Variables
/ 400
Plant Environment
/ 400
Electrical Power
/ 401
Cooling Systems
/ 401
Plant Airflow
/ 402
Housekeeping
/ 402
Pyrometers for Temperature Readings
/ 403
Mold Temperature Balance
/ 404
Resin Melt Temperature
/ 404
Machine Pressure Settings
/ 405
Fine Tuning the Cycle
/ 405
Control by Part Weight
/ 406
Regrind Effects on Part Quality
/ 407
Determining the Missing Variable
/ 408
Taguchi Problem-Solving Techniques
/ 410
Process Control Charting
/ 410
XIV
CONTENTS
Manufacturing
Limits /411
Control
Charts / 412
Measurement-Process Control-Chart Calculations
/ 413
Percent and Fraction Control Charts
/ 422
Percentage Control Chart Formulae
/ 422
Control Limit Calculations for Measurement Data
/ 423
Maintaining Process Control
/ 424
Precontrol
/ 425
Taking Measurements
/ 428
Quality Maintenance
/ 429
Solutions to Typical Molding Problems
/ 429
Shot-to-Shot Variations
/ 429
Cavity Melt Pressure Control
/ 437
Controlling and Monitoring Process Variables
/ 440
Process Line Integration
/ 440
Process Line Integration Benefits
/ 442
Process Line Integration Scheduling
/ 443
Selecting a System
/ 444
12.
Part Testing at the Machine
446
Selecting the Test
/ 446
Verifying Molding Conditions
/ 448
Destructive Tests
/ 448
Gardner Ball Drop Impact Test
/ 449
Nondestructive Tests
/ 450
Optical Comparators
/ 450
Stress/Strain Part Evaluation
/ 451
Polarized Light
/ 451
Aesthetic Part Checking
/ 452
Color Checks
/ 454
Testing of Plated Parts
/ 457
Post-Mold Shrinkage Testing
/ 457
Conditioned Parts
/ 457
13.
Part Handling and Packaging
459
Planning
/ 459
Part Removal
/ 461
Part Handling and Packaging
/ 463
CONTENTS
XV
Automatic Part Packaging
/ 463
Robots
/ 465
14.
Part Design Influence
467
Selecting the Correct Design Parameters
/ 467
Material Selection
/ 468
Part Design for End-Use Applications
/ 469
Radii
/ 470
Nonuniform
Part Thickness
/ 474
Ribs for Strength and Quality
/ 478
Weld-Line Considerations
/ 480
Surface Appearance Problems
/ 484
Bosses
/ 485
Threads
/ 487
Undercuts
/ 490
Inserts
/ 493
Insert Loading
/ 495
Integral Hinges
/ 497
15.
Assembly Techniques
499
Plan for Assembly
/ 499
Automated Assembly
/ 500
Automated Inspection
/ 501
Assembly Techniques
/ 501
Press Fits
/ 502
Snap Fit
/ 503
Welding Assemblies
/ 506
Hot-Plate Welding
/ 529
Focused Infrared Melt Fusion
/ 529
Cold or Hot Heading
/ 531
Mechanical Fasteners
/ 533
Adhesive and Solvent Bonding
/ 538
16.
Decorating Considerations
543
Control of the Process
/ 543
Decorating Techniques
/ 544
Surface Preparation
/ 545
Molded Colors
/ 547
Surface Finish
/ 552
XVI
CONTENTS
Painting
/ 552
Paint System
/ 553
Part
Cleanliness
/ 555
Part Paint
Specifications
/ 556
Graphics
/ 557
Silk Screen /
558
Pad Printing
/ 558
Hot Stamping
/ 559
Heat Transfer
/ 562
Spray and Wipe
/ 562
Two-Shot Molding
/ 562
In-Mold Decorating
/ 564
Vacuum Metallizing
/ 565
Electroplating
/ 568
Flocking
/ 570
Gravure
Decorating
/ 570
17.
Customer and Employee Satisfaction
573
Quality Awareness
/ 574
Appendix A. Quality Management System (QMS) Control
of Documents Procedure
576
Appendix B. Design of Experiments (DOE): Statistical
Troubleshooting Process Screening for Reducing the
Number of Variables
579
Appendix C. Checklists
593
Appendix D. Supplier Evaluation Survey
663
Appendix E. Mold Problem Solutions
675
Appendix F. Decoration
&
Information Solutions
683
Glossary
692
Bibliography
731
Index
740
|
| any_adam_object | 1 |
| author | Gordon, M. Joseph |
| author_facet | Gordon, M. Joseph |
| author_role | aut |
| author_sort | Gordon, M. Joseph |
| author_variant | m j g mj mjg |
| building | Verbundindex |
| bvnumber | BV035656603 |
| callnumber-first | T - Technology |
| callnumber-label | TP1150 |
| callnumber-raw | TP1150 |
| callnumber-search | TP1150 |
| callnumber-sort | TP 41150 |
| callnumber-subject | TP - Chemical Technology |
| classification_rvk | ZM 8160 |
| ctrlnum | (OCoLC)390883539 (DE-599)BVBBV035656603 |
| dewey-full | 668.412 |
| dewey-hundreds | 600 - Technology (Applied sciences) |
| dewey-ones | 668 - Technology of other organic products |
| dewey-raw | 668.412 |
| dewey-search | 668.412 |
| dewey-sort | 3668.412 |
| dewey-tens | 660 - Chemical engineering |
| discipline | Chemie / Pharmazie Werkstoffwissenschaften / Fertigungstechnik |
| edition | 2. ed. |
| format | Book |
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| id | DE-604.BV035656603 |
| illustrated | Illustrated |
| indexdate | 2024-07-09T21:42:36Z |
| institution | BVB |
| isbn | 9780470229637 0470229632 |
| language | English |
| oai_aleph_id | oai:aleph.bib-bvb.de:BVB01-017711089 |
| oclc_num | 390883539 |
| open_access_boolean | |
| owner | DE-703 DE-29T |
| owner_facet | DE-703 DE-29T |
| physical | XVIII, 746 S. Ill., graph. Darst. |
| publishDate | 2010 |
| publishDateSearch | 2010 |
| publishDateSort | 2010 |
| publisher | Wiley |
| record_format | marc |
| series2 | Wiley series in plastics engineering and technology |
| spelling | Gordon, M. Joseph Verfasser aut Total quality process control for injection molding M. Joseph Gordon 2. ed. Hoboken, NJ Wiley 2010 XVIII, 746 S. Ill., graph. Darst. txt rdacontent n rdamedia nc rdacarrier Wiley series in plastics engineering and technology Injection molding of plastics / Quality control Injection molding of plastics Quality control Prozessüberwachung (DE-588)4133922-8 gnd rswk-swf Spritzgießen (DE-588)4056561-0 gnd rswk-swf Totalkontrolle (DE-588)4219255-9 gnd rswk-swf Qualitätskontrolle (DE-588)4047968-7 gnd rswk-swf Spritzgießen (DE-588)4056561-0 s Qualitätskontrolle (DE-588)4047968-7 s Prozessüberwachung (DE-588)4133922-8 s DE-604 Totalkontrolle (DE-588)4219255-9 s 1\p DE-604 Digitalisierung UB Bayreuth application/pdf http://bvbr.bib-bvb.de:8991/F?func=service&doc_library=BVB01&local_base=BVB01&doc_number=017711089&sequence=000002&line_number=0001&func_code=DB_RECORDS&service_type=MEDIA Inhaltsverzeichnis 1\p cgwrk 20201028 DE-101 https://d-nb.info/provenance/plan#cgwrk |
| spellingShingle | Gordon, M. Joseph Total quality process control for injection molding Injection molding of plastics / Quality control Injection molding of plastics Quality control Prozessüberwachung (DE-588)4133922-8 gnd Spritzgießen (DE-588)4056561-0 gnd Totalkontrolle (DE-588)4219255-9 gnd Qualitätskontrolle (DE-588)4047968-7 gnd |
| subject_GND | (DE-588)4133922-8 (DE-588)4056561-0 (DE-588)4219255-9 (DE-588)4047968-7 |
| title | Total quality process control for injection molding |
| title_auth | Total quality process control for injection molding |
| title_exact_search | Total quality process control for injection molding |
| title_full | Total quality process control for injection molding M. Joseph Gordon |
| title_fullStr | Total quality process control for injection molding M. Joseph Gordon |
| title_full_unstemmed | Total quality process control for injection molding M. Joseph Gordon |
| title_short | Total quality process control for injection molding |
| title_sort | total quality process control for injection molding |
| topic | Injection molding of plastics / Quality control Injection molding of plastics Quality control Prozessüberwachung (DE-588)4133922-8 gnd Spritzgießen (DE-588)4056561-0 gnd Totalkontrolle (DE-588)4219255-9 gnd Qualitätskontrolle (DE-588)4047968-7 gnd |
| topic_facet | Injection molding of plastics / Quality control Injection molding of plastics Quality control Prozessüberwachung Spritzgießen Totalkontrolle Qualitätskontrolle |
| url | http://bvbr.bib-bvb.de:8991/F?func=service&doc_library=BVB01&local_base=BVB01&doc_number=017711089&sequence=000002&line_number=0001&func_code=DB_RECORDS&service_type=MEDIA |
| work_keys_str_mv | AT gordonmjoseph totalqualityprocesscontrolforinjectionmolding |