Increased Productivity Of Injection Molding With Analysis Of . - IJRESM
813International Journal of Research in Engineering, Science and ManagementVolume-1, Issue-12, December-2018www.ijresm.com ISSN (Online): 2581-5792Increased Productivity of Injection Moldingwith Analysis of Overall EquipmentEffectiveness (OEE)Daniel Agung1, Fransisca Debora2, Humiras Hardi Purba31,2,3Master of Industrial Engineering, Mercu Buana University, Jakarta, IndonesiaAbstract: The productivity of a product is important for everycompany. There are 5 injection molds with the highest availableproduction hours in April - July. OEE approach are used tomeasure productivity of the injection mold. Mold SLDX has lowestOEE values, with an average value of 76.6% . Based onmeasurement OEE, performance rate has lowest rate, with 81.8%rather than other approaches. Performance rate of injectionmolding affected by cavity efficiency and cycle time performance.Cavity efficiency become root cause that decrease performancerate of mold SLDX, with average cavity efficiency is 84.13% fromApril- July. Based on 5 whys, wrong sequence on the mold becomeroot cause of problem that cause low cavity efficiency.Improvement is done by modify sequence of the mold and adddetent puller as safety system of the mold to prevent wrongsequence of the mold. There are increasing values of cavityefficiency after modification of mold design from 84.13% to99.23% from August – September. Increasing cavity efficiencyalso increase performance rate of mold SLDX from 81,8% to98.2% from August- September. Increasing performance rate alsoincrease OEE value of mold SLDX from 76.6% to 94.33% fromAugust- September.It is a common TPM metric and key component in leanmanufacturing.One plastic packaging industry company has a very denseproduction process activity in April to July 2018. There are 5injection molds that are ranked highest for the mold categorywhich is the mold with availability production hours, includingMold ALC 40, Mold ALC 80, Mold SLDX, Mold ASGR, andMold PLGD as shown in Fig. 1.Keywords: Injection, Mold, OEE, Cavity, 5 whysFig. 1. Production Hours of 5 injection molds period April – July 20181. IntroductionIncreased productivity in an industrial company is animportant role that must be carried out continuously to be ableto be competitive with similar industrial companies. Inovercoming competitiveness among similar companies (forexample, plastic packaging industry companies) in Indonesia,especially those in the Cikarang area, companies must have astrategy to dominate the market by giving satisfaction tocustomers in quality and fulfillment of customer demand. Thestrategy carried out by the company is by prioritizing the qualityof three important indicators in the process of making plasticpackaging which include the performance of machines,materials and molds [1].Overall Equipment Effectiveness (OEE) is a method that canimprove productivity. This can be measured by the productionactivities carried out should be appropriate to the workstandards. OEE has a systematic calculation process to identifyall productivity losses so that it can streamline resources and thelevel of production performance. OEE is a comprehensivemeasurement of how well it performs a given design capacity.After OEE calculation is applied to the injection mold, andshowed that mold SLDX get the OEE values from April- July2018 as low as 75.60% as shown in Table 1.Table 1OEE of 5 Mold period April – July 2018Apr - July 2018ARPRQRMold(%)(%)(%)MOLD ALC 4090.9%93.4%99.3%MOLD ALC 8092.0%97.4%99.3%MOLD SLDX93.7%82.2%99.3%MOLD ASGR97.1%97.5%99.5%MOLD 2.14%Based on OEE calculations specifically from moldSLDX, the results show that the Performance Rate of moldSLDX is as low, with an average of 81.8%, and the lowest inJune with a figure of 72% as shown in Table 2.OEE Result of MOLD SLDX is specifically calculated fromApril – July 2018 and shown in Fig. 3. As shown in Fig. 2, OEEResult is below the standard of OEE World Class in 85%, so
International Journal of Research in Engineering, Science and ManagementVolume-1, Issue-12, December-2018www.ijresm.com ISSN (Online): 2581-5792the improvement must be done to increase OEE and gain worldclass standard.Table 2OEE of Mold SLDX period April – July 2018MOLD 8%76.6%2. Literature reviewA. Injection MouldingInjection molding is an important manufacturing process inthe production of bulk plastic products in complex shapes andsizes with high precision. [2] Injection Molding is the processof conducting the formation of articles using a liquid plasticmaterial, for compacted and then released by opening the twopart mold [3]. The injection molding process can be done inseveral stages, including [4]:1) Selection and adjustment of the product to beproduced to the specifications of plastic such astensile strength, compressive strength, rigidity, etc.2) Preparation process injection, with predefinedparameters.3) Injection the meld resin to the cavity and thenallowing it to solidify.4) Take the final product from the moldB. Overall Equipment Effectiveness (OEE)OEE developed by Seiichi Nakajima in 1960 to evaluate howeffectively a manufacturing operation is used [5]. OEEprocedures focused on the concept of zero waste [6]. Bycalculating OEE, it can be seen that 3 (three) importantcomponents that influence the effectiveness of the machine areavailabilty, performance rate, and quality rate [7].𝑂𝐸𝐸 𝐴𝑣𝑎𝑖𝑙𝑎𝑏𝑖𝑙𝑖𝑡𝑦 𝑥 𝑃𝑒𝑟𝑓𝑜𝑟𝑚𝑎𝑛𝑐𝑒 𝑥 𝑄𝑢𝑎𝑙𝑖𝑡𝑦(1)The calculation of OEE develop continuous improvement bycreating added value for the company [8]. In such efforts, theOEE approach should be pursued to achieve the value of OEEto be closer to the target of world standard value [9]. The worldstandard of OEE is the availability rate is 90%, the performancerate is 95%, and the quality rate is 99% with OEE worth 85%[10].Availability Time is the availability of a machine / equipmentthat produces a comparison between operating times (operatingtime) to the preparation time (loading time) of a machine /equipment [11]. Performance rate is a benchmark of theefficiency of a machine's performance running the productionprocess. Performance rate, measuring the output deviation fromideal time [12]. Quality Rate is the ratio of the number of good814products to the number of products processed [13].C. Root Cause Analysis (RCA)Root Cause Analysis (RCA) is an analytical technique that isgradually and focus more on finding the root cause of theproblem, and not just look at the symptoms of a problem [14].The purpose of RCA is to determine how to save problems bydesigning prevention that recognizes and removes the rootcauses [15]. The steps of RCA are identifying and clarifyingundesired outcomes, devoting data, placing events andconditions on event and causal table factors (incident tables andcausal factors), use a table of causes or other methods to identifyall potential causes, identify the failure mode to the bottomfailure mode, and continue the "why" question to identify themost critical root causes [16].3. MethodologyData processing is done in order to resolve the problem understudy is to:A. OEE analysis from Mold SLDXA1. Calculation of Availability Rate (AR) from Mold SLDXAvailability rate calculation based on the data from theoperating time (is the time when mold produces products) andthe time of loading. This calculation determines the extent ofthe machines' willingness to operate or the utilization of theequipment. The AR calculation is performed by the 𝑛𝑔 ��𝑖𝑡𝑦 𝑅𝑎𝑡𝑒 𝑥 �𝑦 𝑇𝑖𝑚𝑒A2. Calculation of Performance Rate (PR) from Mold SLDXPerformance rate calculation based on availability time, totalcavities in mold, target production quantities (TPQ), and idealcycle time. The PR calculation is performed by the 𝑒 𝑇𝑖𝑚𝑒 𝑥 𝑇𝑜𝑡𝑎𝑙 𝐶𝑎𝑣𝑖𝑡𝑖𝑒𝑠(3)𝑇𝑃𝑄 𝐶𝑦𝑐𝑙𝑒 ��𝑐𝑒 𝑅𝑎𝑡𝑒 𝑂𝑢𝑡𝑝𝑢𝑡𝑇𝑃𝑄x 100 %(4)A3. Calculation of Quality Rate (QR) from Mold SLDXQuality rate calculation based on output and defect product.The QR calculation is performed by the following equation:𝑄𝑢𝑎𝑙𝑖𝑡𝑦 𝑅𝑎𝑡𝑒 𝑂𝑢𝑡𝑝𝑢𝑡 �� 100%(5)A4. OEE calculation from Mold SLDXOEE in Action: OEE taken a manufacturing unit and thenbreaks down its performance into 3 different componentsnamely: Availability Rate, Performance Rate, and Quality Rate.The OEE calculation is performed by the following equation:𝑂𝐸𝐸 𝐴𝑣𝑎𝑖𝑙𝑎𝑏𝑖𝑙𝑖𝑡𝑦 𝑥 𝑃𝑒𝑟𝑓𝑜𝑟𝑚𝑎𝑛𝑐𝑒 𝑥 𝑄𝑢𝑎𝑙𝑖𝑡𝑦(6)B. Study frameworkThe framework of this study is illustrated in Fig. 2, which isin two parts.
815International Journal of Research in Engineering, Science and ManagementVolume-1, Issue-12, December-2018www.ijresm.com ISSN (Online): 2581-5792Table 4Performance Rate (PR) of Mold SLDX period April – July 2018Performance RateTargetOutputCycleTotal Cav.MonthProduc.PR (%)(pcs)Time (s)(pcs)Qty. (pc )April 26563818832320082.2%May 73797818886880084.9%June 46087218864000072.0%July 62857518871360088.1%Average81.8%shown in Table 4. As shown below, the performance rate is lowenough, with the average between April-July 2018 is 81.8 %,Table 5Table title comes hereMonthOutput t (pcs)1304250679782937AverageFinishGood (pcs)264334735472452894625638QR (%)99.5%99.7%98.3%99.5%99.2%below 95% which is Performance Rate World Class standards.Fig. 2. Study Framework4. ResultA. OEE analysis from Mold SLDXTable 3Availability Rate (AR) of Mold SLDX period April – July 2018Availability RateAvailableDownOperatingMonthAR (%)Time (s)Time (s)Time 8000149760093.3%Average94.3%A1. Percentage of Availability Rate (AR) from Mold SLDXThe results of the AR Mold SLDX period April - July 2018shown in Table 3. As shown below, the availability rate stillhigh enough, with the average between April-July 2018 is 94.3%, above 90% which is Availability Rate World Classstandards.A2. Percentage of Performance Rate (AR) from Mold SLDXThe results of the PR Mold SLDX period April - July 2018MonthAprilMayJuneJulyAverageCavity Eff. (%)87.50%83.06%77.80%88.16%84.13%A3. Percentage of Quality Rate (AR) from Mold SLDXThe results of the QR Mold SLDX period April – July 2018shown in Table 5. As shown below, the quality rate is highenough, with the average between April-July 2018 is 99.2 %,above 99% which is Quality Rate World Class standards.Table 6OEE of Mold SLDX period April – July 2018MonthOEE ( % .6%B. Percentage OEE from Mold SLDXThe results of the QEE Mold SLDX period April - July 2018shown in Table 6. As shown below, based on calculationAvailability Rate x Performance Rate x Quality Rate, OEEfrom April – July 2018 has average 76.6% and it still below85% which is OEE World Class Standard.Based on Availabilty Rate Analysis, Performance RateAnalysis, Quality Rate Analysis, and OEE Analysis, concludedthat Performance Rate give significant result to decrease OEE.Compared to Availability Rate & Quality Rate, PerformanceRate is the only parameter that below standard Therefore,conclusion is the main problem start from Performance Rate.Table 7Cavity Efficiency of Mold SLDX period April – July 2018KPI of Cavity Eff.Actual Cycle Time (s)Stand. Cycle Time (s)100%1818100%1818100%1818100%1818100%1818Eff. of Cycle Time100%100%100%100%100%
International Journal of Research in Engineering, Science and ManagementVolume-1, Issue-12, December-2018www.ijresm.com ISSN (Online): 2581-5792816Fig. 3. Root Cause Analysis (RCA) of Mold SLDX period April–July 2018No.1234Suspected CauseWrong sequence on themoldMiscalculation of Pressure& Force on the moldRough surface on O RingGrooveWrong fitting process onthe mold5Material contamination6No standard parameters forprocessTable 8Countermeasure Analysis of Mold SLDX period April – July 2018Action ItemResponsibleFindingCorrection of mold sequenceMold MaintenanceMold sequence is not completely safeSafety system for mold sequence is notSafety system for mold sequenceMold MaintenanceavailableCorrection of pressure & force calculationPressure & force calculation on theProcess Engineeron the moldmold is correctO Ring Groove is not rough and stillPolishing on O Ring GrooveMold Maintenancehas radius for the grooveCorrection on fitting and greasingMold MaintenanceMold is on correct fitting positionprocedure of the moldDevelop filtering system to preventMaterial PreparationMaterial contamination is not foundmaterial contaminationStandard parameter for process alreadyDevelop standard parameter for processProcess EngineermadeBased on an analysis of Performance Rate, in InjectionMolding, Performance Rate is influenced by two factors,namely the cycle time and cavity efficiency. Cavity Efficiencybecomes concern, because it is below the standard KPI ofCavity Efficiency, meanwhile Cycle Time still stable and samewith the standard.C. Calculation of Cavity EfficiencyThe results of the Efficiency Mold Cavity SLDX periodApril-July 2018 shown in Table 7.Target of Cavity Efficiency is 100%, while the result fromApril – July 2018 is below standard. Based on Cavity Efficiencyanalysis, concluded that Cavity Efficiency become criticalfactor that decrease Performance Rate of Mold SLDX.D. Root Cause Analysis (RCA)The results of analysis of Root Cause Analysis (RCA) inMold SLDX period April-July 2018 shown in Fig. 3. RootCause Analysis used is 5 Why Analysis. Cavity Efficiencybelow standard caused by blocked cavity on the mold. Blockedcavity on the mold caused by mold problem and processproblem.E. Countermeasure analysisResults Countermeasure Analysis on the Mold SLDX periodApril-July 2018 shown in Table 8. Countermeasure analyzed bypossible root cause shown in Fig. 3.F. ImplementationAs previously reviewed, dented on mold component causedby friction between mold components. Friction happenedbecause there are wrong sequences on mold mechanism asshown Figure 4. Wrong sequences happened on moldmechanism are:1. Mold close2. Slider plate close & Core Plate forward into cavity plate
817International Journal of Research in Engineering, Science and ManagementVolume-1, Issue-12, December-2018www.ijresm.com ISSN (Online): 2581-57923. Injection process4. Slider plate open, core plate backward5. Slider plate stucked on cavity plate6. Core plate move backward while slider plate still stuckedon cavity plate.7. Friction happened between slider plate and core plate8. Mold dented and cavity must be blocked to prevent defectFig. 6. Mold OpenFig. 4. Detend on mold component SLDXImprovement must be done to guarantee the mechanism ofmold safety. As previously explained, the wrong sequencehappened when slider plate stucked on cavity plate. Whenslider plate stucked on cavty plate, the slider plate cannot beopened, but the core move backward. Improvement must bedone to prevent the slider plate stucked on cavity plate. Thecorrect one is the slider plate must follow the movement of coreplate. When the slider plate follow the movement of core plate,slider plate can be opened and the friction will not happen, soimprovement must be done to make the slider plate followmovement of core plate. Slider plate can follow movement ofcore plate if there are some mechanism that pull the slider plateinto core plate, so that improvement made by modify design ofmold. With additional component, named Detent Puller, themechanism to pull slider plate into core plate can be happened.Fig. 5 shown design of mold after improvement when closedposition. Fig. 6 with shown position of mold when opened.After detent puller added into mold, the sequence change andsafety. The sequence are:1. Mold close2. Slider plate close & Core Plate forward into cavityplate3. Injection process4. Slider plate open, core plate backward5. Slider plate pulled by detent puller to follow core platemovement6. Core plate move backward and slider plate open7. There are no contact and no friction between core plateand slider plateG. Goal settingGoal setting of improvement is 100% of cavity efficiency asshown in Table 9.Table 9Goal setting of cavity efficiency improvementCurrent ConditionGoalCavity Efficiency 84.13%Cavity Efficiency e 10Goal setting of OEE improvementCurrent ConditionGoalOEE 76.62%OEE ing cavity efficiency of mold, will increasePerformance Rate and also OEE of the mold. Increasing cavityFig. 5. Mold Close
818International Journal of Research in Engineering, Science and ManagementVolume-1, Issue-12, December-2018www.ijresm.com ISSN (Online): 2581-5792efficiency, with target 100% Cavity efficiency, also OEE willincrease. OEE Goal setting of the mold is 85%, which is WorldClass OEE Standard, as shown in Table 10.H. Final resultImplementation of improvement done when detent pulleralready assembled on the mold. Cavity efficiency measurementafter improvement start from August – September 2018. Asshown in Table 11, cavity efficiency already increased fromaverage 84.13% from April- July 2018 to 99.23% from AugustSeptember 2018. As shown, the result still below the target,which is 100%.Availability Rate, Performance Rate and Quality Rate arealso measured from August – September 2018 with resultshown in Table 12, Table 13, and Table 14. There are someimprovement in Availability Rate, which before improvementis 94.3% average from April- July 2018 to 96.4% average fromAugust- September 2018 with the result in Table 15.The most significant improvement is in Performance Rate,which before improvement is 81.8% average from April- July2018 to 98.2% average from August- September 2018 with theresult in Table 13.5. Conclusions and recommendationsIn the study resulted in an increase in the average percentageof cavities where previously the average percentage of cavitiesin April - July 2018 was 84.13% while after improvement theaverage percentage of cavities in August - September 2018 was99.23% as shown in the Figure 15 and OEE percentage increasefrom 76.6% in April-July 2018 to 94.33% in August-September2018.References[1][2]A. L. Tucker, The impact of operational failures on hospital nurses andtheir patiens, Journal of Operation Management, 22(2), 2004, 151-169.S. Rajalingam, P. Vasant, Optimization of Injection Molding ProcessParameters by Response Surface Method, Journal of InformationTechnology & Software Engineering, 6(2), 2016.Table 11Cavity efficiency of Mold SLDX after improvementCavity Efficiency (%)Actual Cycle Time (s)Standard Cycle Time ptemberAverageQuality Rate are also increase, which before improvement is99.2 % average from April- July 2018 to 99.7% average fromAugust- September 2018 with the result in Table 14.There are some significant improvement in OEE, caused bysignificant improvement in Performance Rate, which beforeimprovement is 76.62% average from April- July 2018 to93.93% average from August- September 2018 with the resultin Table 15.Table 12Availability Rate (AR) of Mold SLDX after improvementAvailability RateAvailable Time (s)Downtime (s)Operating Time 5001795500Efficiency of Cycle Time100%100%100%AR (%)97.6%95.1%96.4%Output (pcs)812475813199812837Table 13Performance Rate (PR) of Mold SLDX after improvementPerformance RateCycle Time (s)Total Cavities (pcs)Target Production Quantities erAverageTable 14Quality Rate (QR) of Mold SLDX after improvementQuality RateOutput (pcs)Defect (pcs)Finish Good 496Table 15OEE of Mold SLDX after improvementOEEMonthOEE ( % )August94.72%September 93.93%Average94.33%QR (%)99.8%99.7%99.7%PR ( % )97.3%99.1%98.2%
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which is the mold with availability production hours, including Mold ALC 40, Mold ALC 80, Mold SLDX, Mold ASGR, and Mold PLGD as shown in Fig. 1. Fig. 1. Production Hours of 5 injection molds period April - July 2018 After OEE calculation is applied to the injection mold, and showed that mold SLDX get the OEE values from April- July
Injection pressure should be set considering the mold construction and other molding conditions, but generally 49 to 118MPa will be enough. Reny molding recommends relatively high resin temperature of 130 . Reny has good flow property, so burr might occur depending on the molding condition. Avoid molding only by the primary pressure, and use
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