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Tuesday, June 24, 2014

SYSTEMATIC OPERATION OF INJECTION MOULDING MACHINE





Introduction
Injection moulding is a major manufacturing process in producing parts from both thermoplastic and thermoset plastic materials. Injection moulding is widely used for manufacturing various geometry of parts, from the smallest component to entire body of cars component.


Objectives
Upon completion of the course, the participants should be able to:
a)        Operate injection moulding machine with better understanding about machine and its capabilities.
b)       Operate machine with fill and pack procedure.
c)        Translate machine data into a certain useful documentation.
d)       Use proper and safe procedure when operating injection moulding machine.
e)       Optimise the injection moulding process with is prescribe the part quality.
f)         Determine common moulding problems, their causes and remedies.


Course contents
1.          The terminologies and machine overview
2.          The injection moulding process
Mould construction and component
-   Basic mould design
-   Clamping Tonnage calculation
-   Clamping parameter set-up
3.          Introduction of plastic material
-   Type of polymerisation process
-   Type of plastic material
-   Setting up temperature parameter
4.          Setting up Injection parameter
-   Mould filling study
-   In mould rheology curve
-   Injection speed linearity
-   Cavity imbalance
-   Determine of holding phase
-   Determine of gate freeze of time
-   Determine of melt cushion
5.          Process optimization
-          Injection Pressure limitation
-          Injection speed limitation
-          Clamping force limitation
-          Cycle time limitation
-          Pressure loss study
-          Load sensitivity study
-          Tie bar usage guide


Training Method
Training will be delivered through a combination between theoretical   talk, demonstration and practical lessons.


Target Group
This injection moulding course is designed to improve the moulding process from traditional method to systematic approach of injection moulding operation.  The course is suitable to all personnel, who ever involve in injection moulding manufacturing such as lecturer, manager, engineer, machine operators, quality inspector or process technicians.


Course Instructor
The instructor for this course is Mr. Mohamad Rizuaden Bin Razali, who is an instructor of plastic technology since 2001 at ILP Jitra. Mr. Mohamad Rizuaden Bin Razali also has a 6 years of industrial experience in injection moulding process. He has taught many courses on plastic technology to both local and international participants. Mr. Mohamad Rizuaden Bin Razali is certified as a master moulder 1 by  RJG INC (USA).


Course Schedule
Day 1
08:30 a.m.       Briefing & Registration
09.00 a.m        Injection moulding & machine overview
10:00 a.m        Break
10:30 a.m.       Cont.
01:00 p.m.       Lunch
02:00 p.m.       Practical machine operation & parameter setting
05:30 p.m.       End of day 1







Day 2
08:30 a.m.       Clamping unit & mould design
10:00 a.m        Break
10:30 a.m.       Cont.
01:00 p.m.       Lunch
02:00 p.m.       Practical machine operation & parameter setting
05:30 p.m.       End of day 2

Day 3
08:30 a.m.       Basic hydraulic application
10:00 a.m        Break
10:30 a.m.       Cont.
01:00 p.m.       Lunch
02:00 p.m.       Practical machine operation & parameter setting
05:30 p.m.       End of day 3

Day 4
08:30 a.m.       Basic polymer
10:00 a.m        Break
10:30 a.m.       Cont.
01:00 p.m.       Lunch
02:00 p.m.       Practical machine operation & process optimization
05:30 p.m.       End of day 4

Day 5
08:30 a.m.       Plastic temperature injection phase
10:00 a.m        Break
10:30 a.m.       Cont.
01:00 p.m.       Lunch
02:00 p.m.       Practical machine operation & process optimization
05:30 p.m.       End of day 5

Day 6
08:30 a.m.       Holding phase and cooling phase
10:00 a.m        Break
10:30 a.m.       Cont.
01:00 p.m.       Lunch
02:00 p.m.       Practical machine operation & process optimization
05:30 p.m.       End of day 6



Day 7
08:30 a.m.       Injection moulding economic
10:00 a.m        Break
10:30 a.m.       Cont.
01:00 p.m.       Lunch
02:00 p.m.       Practical machine operation & process optimization
05:30 p.m.       End of day 7


Day 8
08:30 a.m.       Trouble elimination
10:00 a.m        Break
10:30 a.m.       Cont.
01:00 p.m.       Lunch
02:00 p.m.       Practical machine operation & process optimization
05:30 p.m.       Closing ceremony


Contact Person
To obtain more information regarding this course, please contact Corporate and Lifelong Learning Section. (04- 9161926 ext 161 or 162). You can also send enquiries by email to bklh@ilpjitra.gov.my


Fees
Companies sending their employees to this course may apply for reimbursement from HRDF under the SBL scheme.
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ILP Jitra - Leader In Skills Excellence


i)Vision : To be a leading organization in the development of competitive workforce

ii)Mission: To produce competent workforce

iii)Objectives:
i-To aide in the direction of optimum utilization of Manpower through Industrial Training Programs.

ii-To improve the standard of skills among workers in the industrial sector.

iv)Core Values:

Access and Equity- Our services are available to everyone who needs them

Quality- A qualification from us should be acknowledged as a sign that the person has received quality training

Continuous improvement- We are always looking for ways to improve services to our clients

Respect for industry -We adapt our services to meet the needs of industry

Integrity -We are committed to the highest standards of ethical behavior

Community -We build partnerships with people and organizations who share our ideals so that together we can achieve more for our clients

Service- We exist to serve our country and industry

v)Corporate Strategy:

Our experienced course managers will serve as strategic partners in order to understand your specific business needs, challenges and requirements. Our consultative and collaborative approach allows our team to develop a sound strategy with clear objectives and outcomes. The insight we gain through our strategic approach will ensure your business receives competency-based, innovative and results-driven training, by the best trainers in the business.

vi)Quality Policy:

A qualification from us should be acknowledged as a sign that the person has received quality training

Please explain the method of formulating the corporate strategy

Experienced course managers will serve as strategic partners in order to understand your specific business needs, challenges and requirements .We will use CUDBASS techniques to find out the weakness and come out with the best solution to narrow down the gap among employees and help clients to boost their performance and profitability.


TRAINING PROGRAM DEVELOPMENT
All training programs including its curriculum structure developed follow National Occupational Skills Standards (NOSS). NOSS is a document that outlines the dexterity required of an employee working in Malaysia at a certain level of employment to achieve specific skills. This Standard was prepared by industry experts and skilled workers in related fields. Its help Skills Training Institute /Trainer/Instructor:
i. To develop an appropriate training curriculum which meets industry needs
ii. To design a full-time training program or customized program that meets industry needs
iii. To have a clearer understanding of the skills required by the industry
iv. Basic assessment of re- training needs of instructors/trainers to meet current industry needs
v. Proper career advice may be given effectively to trainees.

Describe the approaches implemented by your company in ensuring quality training programs.
i) Identification of training needs of employers/industries(Please attach any study, market intelligence or survey conducted).

All the training contents will be developed base on NOSS requirement to ensure the skill training programs meets the industry needs and eliminating miss match/gap between training provider and industry /employers needs. It’s also giving us a clear and systematic approach on how to provide skill training to help company and employee to enhance their career.


ii) Internal factors, including upgrading of trainers’ skills (Please provide evidence).

We train our Trainer/Instructor on related skills areas to improve their knowledge, skills and attitude to become the best trainer in skill training every year including sponsored their participation in Malaysia Skill Competition.


Briefly explain the effort put for continuous improvement of the training programs.

We are establishing Corporate and Lifelong Learning Division to lead on continuous improvement of the training programs and worked with the industry on how to produce competent workers.
CUDBASS method will help us to develop special and workable training programmes to benefit our clients.

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