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

Purpose

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

Project Scope

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

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

Systems & Tools

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

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

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