**Optimization of Injection Molding Process**

30 Some Critical Issues for Injection Molding

Zuidema, H.; Peters, G.W.M. & Meijer, H.E.H. (2001). Influence of cooling rate on pVT-data

(October 2001), pp. 1170-1186. ISSN 0021-8995

of semicrystalline polymers. *Journal of Applied Polymer Science*, Vol. 82, No. 5,

**2** 

Stefan Moser

*Germany* 

*Moser Process Consulting,* 

**Effective Run-In and Optimization** 

This chapter is written to give developers and machine operators a better idea how to install robust processes or how to review and optimize these. The clear structure moves from basic introduction to in-depth application of the methods and tools, thus guiding readers through these processes. While this paper cannot replace a further deepening in this matter, it can

Since the publication of my article "Effective Run-In of an Injection Molding Process", (Moser & Madl, 08/2009) I have noticed that both the start phase of an optimization process and the end phase ("verification / validation") are the most critical parts. Due to this problem, I have decided to extend the upcoming article with the following chapters. Increasingly, "Processes Capability" is a necessary basis for accomplishing design transfer with the customer on a valid foundation. Also "Quality by Design" and "Design Space Estimations" are no longer foreign words within the injection molding business. Especially, the medical and automotive businesses call for process validation. This new chapter will,

This procedure will help process' manager move through the setup or optimization process. Most students who joined, for instance, a "Process Capability Statistics"- or a "Design of Experiments" course, have difficulties finding the fulcrum or lever to complete the first steps. Consequently, they often just invest in "trial and error methods" to get their process to work. Also, common paradigms like "change one parameter at a time" will not help accelerate optimization or enable the improvement team to map the whole process, including interactions or nonlinear behaviours. Therefore, this chapter will outline tools to collect the main process factors, identify the disturbance factors and also some more special tools to interpret the impact of these on the process. The best way to get a run in or on optimization process started is to get a "complementary" team of experts at the table. Within in this team, it

**1. Introduction** 

assess its usefulness.

 Familiarization Screening Optimization Robustness Validation Summary

therefore, be divided into the following sections:

**of an Injection Molding Process** 

Stefan Moser *Moser Process Consulting, Germany* 
