What Is Injection Molding Production Process?

What Is Injection Molding Production Process?

Injection Molding Process Flow Chart and Responsibilities of Each Department

Injection Molding Production Flow Chart

The injection molding production flow chart is shown in Figure 10-1.

info-1024-696

Main Responsibilities of Each Department

Companies have differences in the division of functional departments, but the work content must be covered in the corresponding departments. The following explains the main responsibilities of each functional department in injection molding production for professional injection molding suppliers.

Planning Department

①Mainly based on potential and actual customer demands, formulate capacity forecasts for 18 months, one year, half a year, and three months, as well as monthly, weekly, and daily production plans to guide relevant functional departments in equipment, material, and other planning required by custom injection molding manufacturers.

②The planning department dynamically controls weekly and daily plans, guides the daily production of the injection molding department, and adjusts subsequent weekly and daily production plans in a timely manner according to the completion of daily plans.

③When forecasting capacity and formulating production plans, verify product cycle time (CT), scrap rate, equipment utilization rate, equipment-product matching, and other information to ensure the accuracy of plan information for reliable plastic injection molding suppliers.

Logistics Department

①The logistics department mainly formulates raw material and auxiliary material procurement plans according to the production plan while maintaining close coordination with verified injection molding material suppliers.

②Prepares raw materials and auxiliary materials before production according to weekly and daily production plans.

③Responsible for product inbound and outbound warehouse management.

④Assists in handling non-conforming products during warehousing.

⑤Responsible for the daily management and maintenance of molds.

⑥Prepares molds in advance according to the production plan.

⑦Formulates mold maintenance plans according to mold characteristics.

⑧For special molds that require on-machine maintenance or regular maintenance during production, they must be included in the process specification, and the maintenance department performs maintenance according to requirements.

⑨According to the production status and condition status of batch molds, timely repairs defects such as flash and pull damage on molds.

Injection Molding Department

①Organizes mold materials and installs/removes molds according to the plan.

②Organizes process personnel to start up and debug products and conducts self-inspection to confirm the appearance of the first piece.

③After the first piece is confirmed, organizes operators to process products and conducts product self-inspection.

④Packages qualified products and sends them to the warehouse.

⑤Handles rework of non-conforming products in the process according to requirements.

Quality Control Department

①After process personnel debug the product and self-inspect the first piece appearance as qualified, performs first-piece inspection confirmation.

②During normal production, conducts process patrol inspections at the required frequency.

③Responsible for incoming inspection of qualified products.

④Handles non-conforming products according to the non-conforming product process.

⑤Properly records first-piece inspection, patrol inspection, warehouse entry inspection, and provides feedback on production quality abnormalities.

Main Forms Used by the Production Department

①"Production Weekly/Daily Scheduling Plan (Production Instruction Sheet)".

③"Mold Repair/Change Order".

⑤"Injection Molding First Piece/Patrol Inspection Record Form".

⑦"Injection Molding Production Daily Report".

②"Injection Molding Machine Adjustment and Material Change Record Form".

④"Molding Parameter Record Form".

⑥"Injection Molding Packaging and Warehousing Daily Report".

Optimization of Injection Molding Production Process

In the increasingly fierce competitive environment of the injection molding industry, professional injection molding suppliers and custom injection molding manufacturers need to continuously adjust and optimize production management processes to respond quickly to rapidly changing market demands and customer needs. Enterprise management is paying more and more attention to improving efficiency and reducing costs while delivering consistent quality expected from trusted plastic injection molding suppliers. To achieve this, injection molding product factories must do the following in their processes:

① Formulate business management processes, conduct capacity forecasting, and ensure that business acceptance is based on the actual production level and equipment load status of the injection molding factory to prevent unnecessary losses caused by disconnection between production management and business management.

② Standardize the injection molding production management process, design and optimize each process control point, and formulate standard operating instructions for each process control point to keep the production process under control.

③ Establish injection molding process control (IPQC) workflow, clarify the responsibilities of relevant departments, strictly implement during the production process, and continuously improve to ensure product quality meets or exceeds customer requirements expected from experienced injection molding material suppliers and partners.

④ Establish injection molding material management process, clarify the responsibilities of relevant departments, match all materials with the production plan, and ensure material management is under control.

⑤ Establish a rapid resolution process for on-site quality problems, namely the Quick Response Quality Control (QRQC) mechanism, to reduce production line stoppage time and minimize the generation of non-conforming products. The basic principle of QRQC is to stop the continued production of non-conforming products at the first moment, take countermeasures, and resume production as soon as possible.

⑥ Establish effective information communication channels, clarify and standardize communication interfaces and methods, so that various company instructions and plan information can be transmitted upward and downward, coordinated with each other, and executed in a unified manner around the completion of various enterprise indicators and customer project timelines.