M. J. Gordon

Total Quality 2e

• Gebundenes Buch

Produktbeschreibung

This book highlights the importance of quality control for injection molding - the most commonly used plastics manufacturing method. It provides the guidance and information to apply quality assurance methods so that plastic parts are produced "right the first time" and through all manufacturing operations. The book details ways to improve plastics part design and quality, processability, and total manufacturing, and offers detailed information on machinery and equipment. It also updates the first edition with essential information on Six Sigma, ISO 9000, and TS 16949; computer-guided process control techniques; and lean manufacturing methods.

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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.

Produktdetails

• Wiley Series on Plastics Engineering and Technology
• Verlag: Wiley & Sons
• 2. Aufl.
• Seitenzahl: 768
• Erscheinungstermin: 3. Mai 2010
• Englisch
• Abmessung: 240mm x 161mm x 45mm
• Gewicht: 1186g
• ISBN-13: 9780470229637
• ISBN-10: 0470229632
• Artikelnr.: 26173212

Autorenporträt

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.

Inhaltsangabe

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
Monitoring--Communication. 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. Bar Coding: An Aid
in Total Quality Process Control. Regrind Control. Material Handling and
Storage. Regrind Usage. Processing Aids. 8. The Mold. Computer-Integrated
Manufacture. Pre-mold Design Checklist. Tooling. Selecting Materials for
the Mold. Cavity Selection. Runner Systems. Cavity Runner Layout. Runner
System Design. Gating the Part. Sprues and Nozzles. Parting Lines. Side
Core Pulls. Core Selection. Part Ejection. Venting the Cavity. Core
Venting. Positive Cavity Venting. Temperature Control. Cooling Systems.
Mold Connection Types. Cooling Time. Mold Shrinkage. Hot-Runner Molds. Mold
Maintenance. 9. Manufacturing Equipment. Machinery Selection. Process
Control. Electric Injection Molding Machines. Injection Molding Machine
Nomenclature and Operation. Reciprocating Screw Injection Molding Machine.
The Injection Molding Machine. Selecting Barrel Heater Conditions.
Pyrometer. Thermocouples. Mold Fit and Support. Machine and Mold Clamping
Systems. Vented-Barrel Machines. Maintenance of Machinery. 10. Auxiliary
Equipment. Material Feeders and Blenders. Automatic System. Central
Systems. Material Feed to the Injection Molding Machine. Material Blending
at the Hopper. Blending Quality Checks. Color Concentrate Blending. Regrind
Usage. Material Drying. Plant Equipment Cooling Systems. Granulators or
Grinders. Part Removal, Conveyor Systems, and Robots. Quality Inspection
Equipment. Quick Mold Change. 11. Processing. Production Startup for
Process Control. Acceptable Quality Level Limits. Networking Production.
The Injection Molding Process. Injection Molding Startup. Other Molding
Variables. Fine Tuning the Cycle. Regrind Effects on Part Quality.
Determining the Missing Variable. Process Control Charting. Maintaining
Process Control. Quality Maintenance. Solutions to Typical Molding
Problems. Controlling and Monitoring Process Variables. Process Line
Integration. 12. Part Testing at the Machine. Selecting the Test. Verifying
Molding Conditions. Destructive Tests. Nondestructive Tests. Testing of
Plated Parts. Post-Mold Shrinkage Testing. Conditioned Parts. 13. Part
Handling and Packaging. Planning. Part Removal. Part Handling and
Packaging. Automatic Part Packaging. Robots. 14. Part Design Influence.
Selecting the Correct Design Parameters. Material Selection. Part Design
for End-Use Applications. Threads. Undercuts. Inserts. Insert Loading.
Integral Hinges. 15. Assembly Techniques. Plan for Assembly. Automated
Assembly. Automated Inspection. Assembly Techniques. 16. Decorating
Considerations. Control of the Process. Decorating Techniques. Surface
Preparation. Molded Colors. Surface Finish. Painting. Spray and Wipe.
Two-Shot Molding. In-Mold Decorating. Vacuum Metallizing. Electroplating.
Flocking. Gravure Decorating. 17. Customer and Employee Satisfaction.
Quality Awareness. Appendix A. Quality Management System (QMS) Control of
Documents Procedure. Appendix B. Design of Experiments (DOE): Statistical
Troubleshooting Process Screening for Reducing the Number of Variables.
Appendix C. Checklists. Appendix D. Supplier Evaluation Survey. Appendix E.
Mold Problem Solutions. Appendix F. Decoration & Information Solutions.
Glossary. Bibliography. Index.