Establish robust processing conditions using scientific molding principles (such as fill, pack, hold, and cooling profiles) and Design of Experiments (DOE).
- Troubleshooting: Diagnose and resolve manufacturing defects like short shots (incomplete filling), flash (excess plastic), warpage, sink marks, and dimensional variations.
- Tooling &
- Mold Evaluation:
Review mold designs, assess new tooling trials from "off-tool" to initial samples, and recommend design adjustments to improve cycle times and efficiency.
- Continuous Improvement &
- Cost Reduction:
Track and drive projects that lower scrap rates, reduce cycle times, minimize downtime, and cut material consumption.
- Validation &
- Documentation:
Execute process qualifications including IQ, OQ,
and PQ (Installation, Operational, and Performance Qualification) protocols and maintain accurate mold process and setup sheets.
- Cross-Functional Support: Train process technicians, collaborate with the quality team on process capability, and support new product launches