Measuring quality standards in injection moulding

For customers, the quality of parts is one of their top priorities. It’s a top priority for manufacturers too because they want to make sure customers have the best and most consistent products possible

To make sure that our parts are of high quality, we follow national and international standards and perform checks on process and parts. The number of checks and measures used to determine the quality of parts is huge, so we’ve outlined some of the most common and significant ones used.

Failure Mode and Effect Analysis (FMEA)

This analysis focuses on examining the injection moulding process to control any potential errors and their subsequent effects. Examining failure modes means identifying and analysing any defects or problems in the injection moulding process to make sure the risks and effects on customers are minimised as much as possible.

This is part of the effects analysis, which evaluates the potential consequences on the manufacturer and the customer from each risk that may occur in a process. Risk Priority Number (RPN) is one method of completing this analysis. By numbering the risks in order of potential damage and priority, adding up the RPN score and then taking out the highest numbered risks, manufacturers can systemise and target the risks that have the biggest potential impact on customers.

Process capability

Capability analysis is another statistical method that can be used to analyse and identify the potential risks in an injection moulding process. By gathering data from each stage of the process, manufacturers can gain greater visibility over which potentially damaging aspects of the process can be controlled or eliminated. It also means that other processes can be measured against the statistical controls created, making it easier to identify and minimise inefficiencies.

There are two types of variances that can be measured and pose risks to the consistent quality of parts:

1. Common causes of variation. These are identified as factors that cannot be controlled within a machine or by a manufacturer. Usually these are factors within the factory environment such as temperature, humidity or level of power. Although these often cannot be easily controlled or minimised, they can be taken into account during any process analysis, enabling a more accurate analysis of the process’ effectiveness.

2. Special cause variations. These are elements that are unusual and are within the manufacturer’s control. These can include faults in the machinery, in the choice of material or in the parameters of the process. Once these have been identified, the manufacturer can easily minimise or fix them, making the process as efficient as possible

Tolerances

As the main measurement of the quality of a part, knowing the tolerance of a product is essential knowledge for a manufacturer. Once the control measurement for a tolerance has been set, making sure this is monitored closely is essential to ensuring consistent quality products for customers.

There are many factors that can have an impact on tolerances: the choice of material; a part’s geometry and size; and the complexity of the mould that is used could all cause the product to be damaged and affect its tolerance. Once a slip in tolerance has been identified however, manufacturers can start to analyse and change different aspects of the process to get it back within the control limit. Tolerances, like all of the above quality measures, are essential to making sure that the product manufacturers create is consistent and high-performing for customers.

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