A leading automotive manufacturer chooses ATS to optimize injection machine purge process using Six Sigma

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Purpose

  • Optimize the quantity of rubber used in injection machines purge process
  • Avoid contamination of final product due to vulcanization of rubber
Purpose

Project Scope

  • Optimize process parameters to avoid pre-injection vulcanization
  • New parameter and process settings
  • Validate the process settings based on experiments
Project scope

Solution Approach

  • Study the different parameters affecting the rubber vulcanization before injection
  • Different experiments were designed (DOE) to prove the hypothesis established during the analyzing period
  • Enhancing the operator awareness
  • Different process improvement opportunities were identified and embedded into the company planned actions in Continuous Improvement
Solution Approach

The Results

  • 22% reduction in pre-injection vulcanization
  • Approximate cost savings- ~€ 82,000 / year
  • Significant reduction in the amount of material wasted during the purge leading to important material savings
Results

Systems, Tools & Services Expertise

  • DMAIC (Define, Measure, Analyse, Improve, Control)
  • ANOVA
Tools

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