The all-encompassing guide to total quality process control for
injection molding
In the same simple, easy-to-understand language that marked the
first edition, Total Quality Process Control for Injection
Molding, Second Edition lays out a successful plan for
producing superior plastic parts using high-quality controls. This
updated edition is the first of its kind to zero in on every phase
of the injection molding process, the most commonly used plastics
manufacturing method, with an all-inclusive strategy for
excellence. Beginning with sales and marketing, then moving forward
to cover finance, purchasing, design, tooling, manufacturing,
assembly, decorating, and shipping, the book thoroughly covers each
stage to illustrate how elevated standards across individual
departments relate to result in the creation of a top-notch
product. This Second Edition:
* Details ways to improve plastic part design and quality
* Includes material and process control procedures to monitor
quality through the entire manufacturing system
* Offers detailed information on machinery and equipment and the
implementation of quality assurance methods--content that is
lacking in similar books
* Provides problem-analysis techniques and troubleshooting
procedures
* Includes updates that cover Six Sigma, ISO 9000, and TS 16949,
which are all critical for quality control; computer-guided process
control techniques; and lean manufacturing methods
With proven ways to problem-solve, increase performance, and
ensure customer satis-faction, this valuable guide offers the vital
information today's managers need to plan and implement quality
process control--and produce plastic parts that not only meet,
but surpass expectations.
Autorentext
M. Joseph Gordon Jr. is a consultant in the quality/process control and plastics field. He has over thirty-five years' experience in quality assurance, process control, and program management with experience in establishing and maintaining an ISO 9001, ISO 14001, and/or QS-9000/TS 16949 Quality System, Lean Manufacture, and Six Sigma business and manufacturing systems. Mr. Gordon has worked closely with Chrysler, Ford, and General Motors; CTS Reeves (frequency oscillators); and Lockheed Martin and their supplier network requiring tight tolerance products in a variety of materials.
Klappentext
The all-encompassing guide to total quality process control for injection molding
In the same simple, easy-to-understand language that marked the first edition, Total Quality Process Control for Injection Molding, Second Edition lays out a successful plan for producing superior plastic parts using high-quality controls. This updated edition is the first of its kind to zero in on every phase of the injection molding process, the most commonly used plastics manufacturing method, with an all-inclusive strategy for excellence. Beginning with sales and marketing, then moving forward to cover finance, purchasing, design, tooling, manufacturing, assembly, decorating, and shipping, the book thoroughly covers each stage to illustrate how elevated standards across individual departments relate to result in the creation of a top-notch product. This Second Edition:
-
Details ways to improve plastic part design and quality
-
Includes material and process control procedures to monitor quality through the entire manufacturing system
-
Offers detailed information on machinery and equipment and the implementation of quality assurance methodscontent that is lacking in similar books
-
Provides problem-analysis techniques and troubleshooting procedures
-
Includes updates that cover Six Sigma, ISO 9000, and TS 16949, which are all critical for quality control; computer-guided process control techniques; and lean manufacturing methods
With proven ways to problem-solve, increase performance, and ensure customer satis-faction, this valuable guide offers the vital information today's managers need to plan and implement quality process controland produce plastic parts that not only meet, but surpass expectations.
Inhalt
Preface.
1. Total Quality Process Control.
ISO 9001.
Documentation.
Establishing Process Ownership.
Ideas and Methods.
2. Implementing Total Quality Process Control (TQPC).
Quality Improvement Plan.
Statistical Process Control (SPC).
Controlling the Process.
Cp the Control of Operations.
Cpk-Centered Process Control.
Establishing Company Quality Objectives.
Customer Quality.
3. Managing for Success, Commitment to Quality.
Objectives for Managing a Quality System.
Proactive Preventive Action.
Total Quality Process Control.
Principles for Quality Systems Engineering.
Objectives for Managing a Quality System.
Customer-Supplier Quality Agreements.
Product Quality Determination.
Form, Fit, and Function (FFF).
Product Requirements.
Existing Mold Considerations.
Establishment of Responsibility.
Department TQPC Responsibility.
Estimated Piece Part Price.
Multifunctionality.
Assembly and Decorating.
Manufacturing Capability.
Computer-Integrated Manufacture (CIM).
Tracking Manufacture.
RFID.
EDI.
Control of Operations.
Process Control.
Control Charting.
International Organization for Standardization (ISO) Accreditation.
Program MonitoringCommunication.
Communicating Quality in Business.
Communications.
Surveys.
Quality Function Deployment (QFD).
QFD in Operation.
Customer Feedback.
Critical to Quality (CTQ).
Building on TQPC, Product Manufacture.
Checklists.
Quality Circles.
Fishbone Analysis.
Failure Mode and Effects Analysis.
Types of FMEAs.
FMEA Timing.
Implementing an FMEA.
FMEA Development.
4. Customer Satisfaction.
Manufacturing and Supplier Input.
Vendor Selection.
Vendor Survey.
Customer and Supplier Agreements.
Vendor Clinics.
Product Requirements.
Product Preproduction Review.
5. Organization Responsibilities.
Quality Operations.
Quality Uniformity.
Compliance Audits.
Six Sigma Introduction.
Procedure.
Quality Problems.
TQPC Management Operations.
Preventive Action.
6. Establishing the Limits for Quality Control.
Preproduction Product Analysis.
Taguchi Methods.
Prototyping.
Mold Limits.
Material Selection.
Calculation of Plastic Part Cost.
Case Study of Product Cost Analysis.
Estimating Part Cycle Time.
Mold Part Cavity Estimation.
Mold Size Considerations.
Injection Molding Machine Selection.
Melt Generation.
Molding Machine Screw-type Considerations.
Machine Hourly Rate.
Machine Setup Charges.
Calculating Product Manufacturing Cost.
Material Supplier Limits.
Establishing Manufacturing Limits.
Auxiliary Equipment.
In-Process Inspection.
Establishing Total Quality Process Control.
Acceptable Quality Limits.
7. Material Selection and Handling.
Thermosets.
Thermoplastics.
Classifying the Polymers.
Product Certifi cation.
Material Specifi cation.
Product Variable Specification.
Incoming Material Testing.
Material Testing Equipment.
Material Safety Data Sheets.
Record Accuracy.
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