Continuous improvement of injection moulding using Six Sigma: case study

Maged, Ahmed; Haridy, Salah; Kaytbay, Saleh; Bhuiyan, Nadia

doi:10.1504/ijise.2019.10021839

Cited by 9 publications

(15 citation statements)

References 30 publications

Supporting

Mentioning

Contrasting

Unclassified

Order By: Relevance

“…Also, if "Six Sigma" and "plastic injection molding" are searched in the scholarly article database of North Carolina State University library, a few direct articles are found (e.g. Safwat and Ezzat, 2008;Kairulazam, Hussain, Mohd Zain, and Lutpi, 2014;Maged et al, 2019;Timans, Ahaus and Antony, 2014;Lo, Tsai and Hsieh, 2009). Examples include Safwat and Ezzat (2008)'s study in which they applied Six Sigma DMAIC methodology to reduce the percentage of scrap materials in a plastic injection molding facility.…”

Section: Six Sigma Research On Plastic Injection Moldingmentioning

confidence: 99%

“…Similarly, in their study Maged et al (2019) conducted a case study that incorporated Six Sigma DMAIC methodology in plastic injection molding process for quality improvement through defect reduction. The goal of their study was to determine root causes and eliminate major quality issues.…”

Section: Six Sigma Research On Plastic Injection Moldingmentioning

confidence: 99%

“…Mass production of plastic parts that have complex geometries can be achieved at lower costs via injection molding process where solid plastic pellets are melted, injected into a mold, and then cooled back to a new solid shape (Birley, 2012;Khavekar, Vasudevan and Modi, 2017). Accordingly, injection molding has been extensively utilized for manufacturing of a wide range of plastic parts, extending from the smallest components to large body panels (Maged, Haridy, Kaytbay and Bhuiyan, 2019).…”

Section: Introductionmentioning

confidence: 99%

“…Quality issues in injection molding can extend from slight surface defects to major problems that can affect the safety, performance and functionality of the product. These issues can stem from the problems related to materials, part design, labor skills, mold design, machine performance and manufacturing conditions (Maged et al, 2019).…”

Section: Introductionmentioning

confidence: 99%

“…As in many manufacturing processes, keeping quality characteristics under control is sufficient in meeting required specifications (Bharti et al, 2011;Desai and Prajapati, 2017). However, large amounts of scrap due to non-conforming parts cannot be avoided in many plastic injection molding operations (Maged et al, 2019). Therefore, any efforts aimed at quality improvement in plastic parts manufacturing operations may result in substantial financial contribution for companies (Desai and Prajapati, 2017).…”

Section: Introductionmentioning

confidence: 99%

See 4 more Smart Citations

Six Sigma in Plastic Injection Molding: Reuse Defective Parts in New Article Production as Raw Material Input or Not?

Uluskan

2021

Endüstri Mühendisliği

View full text Add to dashboard Cite

In production plants, re-processing of defective products and re-incorporating them into production as raw materials, provides the advantages of reducing scrap and efficient use of material. However, using recycled defective plastic parts as raw materials in the production of new parts in plastic injection processes can create aesthetic problems for the final product. On the other hand, the aesthetic dimension of quality that fulfills customer expectations provides competitive advantage. Considering this, in this study, the root cause of the aesthetic problem that occurs as discoloration of a particular component manufactured in a plastic injection facility operating in the whitegoods industry was revealed and improvement was made. Six Sigma DMAIC methodology was applied to reduce high scrap rates caused by discoloration errors, and it was determined that the error was caused by reusing scrap plastic parts as raw materials in the production of new articles. With the elimination of this cause, the process capability was improved, the 3 sigma process capability was increased to the level of 4.7 sigma and the aesthetic appearance of the product was improved. This study has shown that the reutilization of defective plastic parts as raw material input in new article production is not a viable approach for particular products such as whitegoods products.

show abstract

Section: Six Sigma Research On Plastic Injection Moldingmentioning

confidence: 99%

Section: Six Sigma Research On Plastic Injection Moldingmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

See 3 more Smart Citations

Six Sigma in Plastic Injection Molding: Reuse Defective Parts in New Article Production as Raw Material Input or Not?

Uluskan

2021

Endüstri Mühendisliği

View full text Add to dashboard Cite

show abstract

Improving plastic manufacturing processes with the integration of Six Sigma and machine learning techniques: a case study

Abd Elnaby,

Zaher,

Abdel-Magied

et al. 2023

Journal of Industrial and Production Engineering

View full text Add to dashboard Cite

Application of six sigma through deep learning in the production of fasteners

Altuğ¹

2023

IJLSS

View full text Add to dashboard Cite

Purpose The purpose of this study was conducted at an enterprise that produces fasteners and is one of the leading companies in the sector in terms of market share. Possible defects in the coating of bolts and nuts either lead to products being scrapped or all of the coating process being repeated from beginning to end. In both cases, the enterprise faces a waste of time and excessive costs. Through this project, the six sigma theory and its means were effectively used to improve the efficiency and quality management of the company. The selection of the six sigma project has also contributed to the creation of various documents to be used for project screening and evaluation of financial results. Design/methodology/approach Six sigma is an optimization strategy that is used to improve the profitability of businesses, avoid waste, scrap and losses, reduce costs and improve the effectiveness of all activities to meet or exceed customers’ needs and expectations. Six sigma’s process improvement model, known as Definition-Measurement-Analysis-Improvement-Control, contributes to the economic and technical achievements of businesses. The normal distribution of a process should be within ±3 sigma of the mean. This represents a scale of 99.7% certainty. However, improving the process through the utilization of the six sigma rule, which accepts normal variabilities of processes twice as strict, will result in an error rate of 3.4 per million instead of 2,700 per million for each product or service. Findings Using six sigma practices to reduce the costs associated with low quality and to increase economic added value became a cultural practice. With this, the continuation of six sigma practices throughout the Company was intended. The annual cost reduction achieved with the utilization of six sigma practices can be up to $21,780. When time savings are also considered, a loss reduction of about $30,000 each year can be achieved. The coating thickness efficiency increased from 85% to 95% after the improvements made through the six sigma project. There is a significant increase in the efficiency of coating thickness. In addition, the coating thickness efficiency is also close to the target value of 95%–97%. Originality/value The results of the study were optimized with the help of deep learning. The performance of the model created in deep learning was quite close to the actual performance. This result implicates the validity of the improvement work. The results may act as a guide for the use of deep learning in new projects.

show abstract

Continuous improvement of injection moulding using Six Sigma: case study

Cited by 9 publications

References 30 publications

Six Sigma in Plastic Injection Molding: Reuse Defective Parts in New Article Production as Raw Material Input or Not?

Six Sigma in Plastic Injection Molding: Reuse Defective Parts in New Article Production as Raw Material Input or Not?

Improving plastic manufacturing processes with the integration of Six Sigma and machine learning techniques: a case study

Application of six sigma through deep learning in the production of fasteners

Contact Info

Product

Resources

About