Case Studies

Home > Case Studies > Reduce Material Variance In Molding

Reduce Material Variance In Molding

THE PROBLEM:

Excess consumption of molding resins

BACKGROUND:

In a large manufacturing factory making electronic products, the consumption of raw materials was beyond specified quantities. A black belt project was instituted to identify all possible causes for the loss and drive improvements.

THE SOLUTION:

Analysis of data indicated that one of the high runners had excess flash which led to de-flashing leading to non-value adding activity as well as material waste. It was also found that molded parts which were counted by a weighing cum counting scale had uncertainty in measurements and hence excess parts were added during packing. In this project, two key actions were taken to achieve desired results:

  1. To optimize process parameter settings of Hold Pressure, Injection Time and Injection Speed we carried out a statistical analysis called EVOP (Evolutionary Operation). Several experiments were designed and the results analyzed using a mini-tab software. The step by step process tweaking helped us to arrive at the optimum parameters for molding.
  2. Measurement System Analysis (MSA) helped in identifying the cause for issues in measurement repeatability and reproducibility. This also helped in selecting an appropriate weighing scale based on the accuracy of the scale and the unit weight of the parts measured.

RESULT:

Process optimizations led to reduction of acceptable flash levels and prevented de-flashing activity as well as excess consumption of resins. Improving the MSA of the weighing scale prevented adding excess parts while packing. The changed packing method was validated using a t-test. The overall savings from these improvements as well as other quality improvements was 32K per annum.

Scroll to Top
  • He has personally mentored 550 individuals.
  • He has extensive practical experience and would share the cases handled in the sessions.
  • Trained by Mckinsey Consultants as a Lean Practitioner, Rock Hill-USA
  • Certified MBB in Lean and Six Sigma by SBTI, Texas.
  • He has handled on site training and consulting in global sites at Switzerland, Netherlands, Hungary, Poland, Germany, Belgium, UAE, Srilanka, Thailand, China,Japan, USA and across Indian cities.
  • His online candidates include people from Sweden, Saudi Arabia, Australia, Philippines, PNG, Denmark, Lebanon, Kenya.
  • Certified as CEO Coach by completing Post Graduate Program in Executing Coaching by CFI India.
  • Executive General Management Program, IIM Bangalore.
  • M.Tech. Quality Management from BITS Pilani.

PRADEEP KUMAR

Enroll to our Six Sigma Certification Program

ABRAHAM MATHEWS, SENIOR CONSULTANT

Abraham has more than two decades of experience in Quality Management and Operations, including designing quality, environmental and health & safety management systems, managing industrial engineering activities and heading a Plant.  He is an expert auditor of quality systems and in working with teams to implement robust processes that is sustainable.  Having worked in Aerospace and Automotive industry he understands the Industry requirements and is very meticulous in his approach in implementing the required standards.  He is also a trained Lean practitioner and support training and implementing Lean Manufacturing Systems. He also conducts Yellow belt Six Sigma training and supports Green belt training.

M.BALAJI, Principal Consultant, Management Systems

Balaji is a Mechanical Engineer with four decades of experience with the last thirteen years in Management consultancy.  His expertise is in Management Systems, with extensive experience in training, auditing and supporting implementation of Quality and Environmental Management systems.  He is also a qualified tool designer from NTTF and GTTC.

Balaji keeps abreast of the latest changes in international standards for implementing quality management systems and is a Lead Auditor for ISO 9001, ISO 14001, ISO 9001, ISO 45001, ISO 22163. Also auditor for  IATF 16949.  He is a  Lead Assessor for EXIM Bank award for Business Excellence model .  With more than a decade of experience in management consulting, he has conducted 600 man-days of training and 250 man-days of audits; working with more than 35 clients.

Pradeep Kumar, Chief Executive

Pradeep Kumar has about three decades of professional experience against his name.  With multi-location and multi-cultural exposure paired with a Master Black Belt in Six Sigma & Lean, Pradeep’s core expertise comes from over a decade of specialization in a large multinational manufacturing company. He is a Certified MBB in Lean and Six Sigma by SBTI, Texas and trained by Mckinsey Consultants as a Lean Practitioner in Rock Hill-USA.

He currently works with large multinational companies, helping them drive Operational Excellence and implement lean strategies. Pradeep also guides senior leadership towards excellence in execution. He has trained candidates in Lean & Six Sigma in India, China, Japan, Thailand, Europe, Middle East, Sri Lanka and the USA; and mentored more than 500 Engineers and Managers in Lean & Six Sigma in India and overseas.  His expertise lies in understanding gaps in current systems, designing more effective processes and mentoring teams to swiftly achieve organizational goals