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1.0 INTRODUCTION 1.1 FUJITSU COMPONENT (M) [Link]

Figure 1: Logo Fujitsu

FUJITSU COMPONENT (MALAYSIA) SDN BHD is the electronic company that has been operates since1980 at Parit Raja Batu Pahat, Johor. This company was established to produce coils for electromagnetic relays that assembled by Fujitsu Singapore Private Limited (FSL). Date of this company incorporation is on 9 October 1980 with authorized capital RM200000000.00. This company wholly owned by Fujitsu Takamisawa Component Limited, Japan. Before July1986, assembled process by Fujitsu Singapore Limited, but after July 1986, the assembly process was transferred from FSL to Fujitsu Component Malaysia (FCM), where various kinds of electromagnetic relays are manufactured for a wide range of applications such as electrical equipment and computers, etc. In 1987, FCM started producing keyboards and connectors too, and from 1987 to 1989, the molding, stamping and plating process were transferred to FCM to support the assemble process. Fujitsu Companies has 1508 staff working under Fujitsu Component (Malaysia) which also includes foreign worker, Indonesian 197 worker and Vietnamese 32 worker. Their basic salaries are RM900 per month. All Fujitsu Component staff is given uniform of company and need to wear every time come for working. All uniform are same for all staff except general manager. The color of scarf and hat gives a different post. White color for operator, orange color for quality control, blue color for technician, green for new operator, pink for inspection and white for line leader. All staff also is given two pairs of shoes and need to wear inside production line. For visitors, they are given shoes cover to cover their shoes. All operator work with three shifts, which is morning 7am until 3pm, afternoon 3pm until 11pm and night shift 11pm until 7am. Since establishment, Fujitsu Component Malaysia production scale has progressed rapidly and makes Fujitsu Component Malaysia a major overseas electronics component production base for Fujitsu Limited, Japan. All design for Fujitsu component come from Research and Development department at Japan and assembled at Fujitsu Component Malaysia. Fujitsu Component Malaysia use high level production technology to produces their component that is greatly valued for their high reliability and good quality.

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2.0 OBJECTIVE These projects of Manufacturing Engineering conducted with several objectives. These project determine so the goal of POPBL achievements. The objective of this project:1. 2. 3. 4. To investigate the problem occur during the process of injection molding. To investigate how and why the problem happened during injection molding process. To determine optimum parameter and how to solve the problem. To know the process to produce the product by injection molding.

3.0 EXPLANATION OF THE PROCESS INJECTION MOLDING 3.1 Injection Molding

Figure 2 : Injection Molding Injection molding is the most commonly used manufacturing process for the fabrication of plastic parts. A wide variety of products are manufactured using injection molding, which vary greatly in their size, complexity, and application. The injection molding process requires the use of an injection molding machine, raw plastic material, and a mold. The plastic is melted in the injection molding machine and then injected into the mold, where it cools and solidifies into the final part. Injection molding is used to produce thin-walled plastic parts for a wide variety of applications, one of the most common being plastic housings. Plastic housing is a thinwalled enclosure, often requiring many ribs and bosses on the interior. These housings are used in a variety of products including household appliances, consumer electronics, power tools, and as automotive dashboards.
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Other common thin-walled products include different types of open containers, such as buckets. Injection molding is also used to produce several everyday items such as toothbrushes or small plastic toys. Many medical devices, including valves and syringes, are manufactured using injection molding as well. The process cycle for injection molding is very short, typically between 2 seconds and 2 minutes, and consists of the following five stages: 1) Mold Close and Clamping

Figure 3 : Clamping Prior to the injection of the material into the mold, the two halves of the mold must first be securely closed by the clamping unit. Each half of the mold is attached to the injection molding machine and one half is allowed to slide. The hydraulically powered clamping unit pushes the mold halves together and exerts sufficient force to keep the mold securely closed while the material is injected. The time required to close and clamp the mold is dependent upon the machine - larger machines (those with greater clamping forces) will require more time. This time can be estimated from the dry cycle time of the machine. The mould is closed within the platen arrangement and clamped using necessary force to hold the mould shut during the plastic injection cycle, thus preventing plastic leakage over the face of the mould. Present day moulding machines range from around 15 to 4,000 metric tonnes available clamping force (150 to 4000 kN).Many systems are available for opening/closing and clamping of mould tools, although usually they are of two general types. Direct Hydraulic Lock is a system where the moving machine platen is driven by a hydraulic piston arrangement which also generates the required force to keep the mould shut during the injection operation. Alternatively, smaller auxiliary pistons may be used to carry out the main movement of the platen and a mechanical blocking arrangement is used to transfer locking pressure from a pressure intensifier at the rear of the machine, which moves only by a few millimeters, through to the platen and tool. The second type of general clamping arrangement is referred to as the Toggle Lock.

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2) Injection

Figure 2 : Reciprocating Screw Injection Moulding Unit At this stage in the machine cycle the helical form injection screw (Figure 1) is in a 'screwed back' position with a charge of molten thermoplastic material in front of the screw tip roughly equivalent to or slightly larger than that amount of molten material required to fill the mould cavity. Injection moulding screws are generally designed with length to diameter ratios in the region of 15:1 to 20:1, and compression ratios from rear to front of around 2 : 1 to 4 : 1 in order to allow for the gradual densification of the thermoplastic material as it melts. A check valve is fitted to the front of the screw such as to let material pass through in front of the screw tip on metering (material dosing), but not allow material to flow back over the screw flights on injection. The screw is contained within a barrel which has a hardened abrasion resistant inner surface. The raw plastic material, usually in the form of pellets, is fed into the injection molding machine, and advanced towards the mold by the injection unit. During this process, the material is melted by heat and pressure. The molten plastic is then injected into the mold very quickly and the buildup of pressure packs and holds the material. The amount of material that is injected is referred to as the shot. The injection time is difficult to calculate accurately due to the complex and changing flow of the molten plastic into the mold. However, the injection time can be estimated by the shot volume, injection pressure, and injection power. Normally, ceramic resistance heaters are fitted around the barrel wall, these are used to primarily heat the thermoplastic material in the barrel to the required processing temperature and make up for heat loss through the barrel wall, due to the fact that, during processing most of the heat required for processing is generated through shear imparted by the screw. Thermocouple pockets are machined deep into the barrel wall so as to provide a reasonable indication of melt temperature. Heat input can therefore be closed loop controlled with a Proportional Integral and Derivative (PID) system. The screw (nonrotating) is driven forward under hydraulic pressure to discharge the thermoplastic material out of the injection barrel through the injection nozzle, which forms an interface between barrel and mould, and into the moulding tool itself.

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3) Holding Pressure and Cooling

The screw is held in the forward position for a set period of time, usually with a molten 'cushion' of thermoplastic material in front of the screw tip such that a 'holding' pressure may be maintained on the solidifying material within the mould, thus allowing compensating material to enter the mould as the moulded part solidifies and shrinks. Holding pressure may be initiated by one of three methods: by a set time in seconds from the start of the injection fill phase; by the position of the screw in millimeters from the end of injection stroke; or by the rise in hydraulic pressure as measured by a pressure transducer in the mould itself or in the injection hydraulic system. As the material solidifies to a point where hold pressure no longer has an effect on the mould packing, the hold pressure may be decayed to zero, this will help minimize residual stresses in the resultant moulding. Once the hold pressure phase has been terminated the mould must be held shut for a set period of cooling time. This time allows the heat in the moulding to dissipate into the mould tool such that the moulding temperature falls to a level where the moulding can be ejected from the mould without excessive distortion or shrinkage. This usually requires the moulding to fall to a temperature below the rubbery transition temperature of the thermoplastic or Tg (glass transition temperature). Depending on the type of plastic this can be within a few degrees or over a temperature range. Mould temperature control is incorporated into the tool usually via channels for pressurized water flow. The mould may be connected to a cooling unit or water heater depending on the material being processed, type of component and production rate required. The molten plastic that is inside the mold begins to cool as soon as it makes contact with the interior mold surfaces. As the plastic cools, it will solidify into the shape of the desired part. However, during cooling some shrinkage of the part may occur. The packing of material in the injection stage allows additional material to flow into the mold and reduce the amount of visible shrinkage. The mold cannot be opened until the required cooling time has elapsed. The cooling time can be estimated from several thermodynamic properties of the plastic and the maximum wall thickness of the part. 4) Material Dosing or Metering During the cooling phase, the barrel is recharged with material for the next moulding cycle. The injection screw rotates and, due to its helical nature, material in granule or powder form is drawn into the rear end of the barrel from a hopper feed. The throat connecting the hopper to the injection barrel is usually water cooled to prevent early melting and subsequent material bridging giving a disruption of feed. The screw rotation speed is usually set in rpm which is measured using a proximity switch at the rear of the screw. Screw rotation may be set as one constant speed throughout metering or as several speed stages.

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The material is gradually transferred forward over the screw flights and progressively melted such that when it arrives in front of the screw tip it should be fully molten and homogenised. The molten material transferred in front of the tip progressively pushes the screw back until the required shot size is reached. Increased shear is imparted to the material by restricting the backward movement of the screw, this is done by restricting the flow of hydraulic fluid leaving the injection cylinder. This is referred to as `back pressure' and it helps to homogenise the material and reduce the possibility of unmelted material transferring to the front of the screw. 5) Ejection After sufficient time has passed, the cooled part may be ejected from the mold by the ejection system, which is attached to the rear half of the mold. When the mold is opened, a mechanism is used to push the part out of the mold. Force must be applied to eject the part because during cooling the part shrinks and adheres to the mold. In order to facilitate the ejection of the part, a mold release agent can be sprayed onto the surfaces of the mold cavity prior to injection of the material. The time that is required to open the mold and eject the part can be estimated from the dry cycle time of the machine and should include time for the part to fall free of the mold. Once the part is ejected, the mold can be clamped shut for the next shot to be injected. After the injection molding cycle, some post processing is typically required. During cooling, the material in the channels of the mold will solidify attached to the part. This excess material, along with any flash that has occurred, must be trimmed from the part, typically by using cutters. For some types of material, such as thermoplastics, the scrap material that results from this trimming can be recycled by being placed into a plastic grinder, also called regrind machines or granulators, which regrinds the scrap material into pellets. Due to some degradation of the material properties, the regrind must be mixed with raw material in the proper regrind ratio to be reused in the injection molding process.

Figure 6 : Injection Molded Part

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4.0 THE PROBLEM AND SOLUTION THAT OCCURRED DURING THE PROCESS, THE POSSIBLE CAUSES THAT EFFECT THE PROCESS OR PRODUCT 1) Flash Defect

Figure 7: Flash Defect

The injection molded part defect known as Flash is that thin layer of plastic that flows outside of the cavity where the two halves of the injection mold meet. If the flash has to be manually trimmed off by an operator or some other employee, it becomes a labor-intensive, high cost problem. Plastic parts with flash are usually put in the scrap grinder or just thrown away, depending on the plastic material and company guidelines.

Causes Material is too hot. The injection pressure is too high. The clamping pressure is too low. Worn or poorly fitting cavity/mold plates, including, mold plate deformations and obstructions (grease, dirt, debris) Overpacked sections cause increased localized pressure. An improperly designed venting system, a very poor venting system, or a venting system that is too deep.

Solution Reduce the temperature Lower the injection pressure. Reface the parting line. Increase the clamping pressure. Select machine with higher clamp force. Reduce pressures and shot size to the minimum required. Use the material supplier recommended venting size.

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2) Short Shot

Figure 8 : Short Shot As the name suggests, "short shot" means that not enough resin has flowed into the mold to fill it adequately. The main causes for short shot are the mold condition or flow ability problems with the resin. The problem is alleviated when a greater volume of resin flows more easily. This is done by raising temperature and pressure as well as enlarging the gate to reduce resin resistance. Cause Injection pressure is too low. Resin flows too slowly. Mold temperature is too low and resin viscosity is too high. Resin supply is insufficient. Too much flow resistance is at the sprue, runner and gate. Solution Increase injection pressure. Increase temperature in the cylinder. Increase injection speed. Increase the mold temperature. Increase the resin volume. Increase the sectional area of the gate, sprue and runner, and shorten the length. Make the sprue, runner and gate surfaces more slippery. Change the gate position; increase the thickness of the mold cavity; modify design to improve flow.

Too much flow resistance is at the sprue, runner and gate. Too much flow resistance is in the cavity.

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3) Jetting

Figure 9 : Jetting

Figure 10 : Jetting Formation

"Jetting" is marks on the product surface that look like a worm has crawled across it. When molds have a small cold slug well, the cool resign that comes out of the nozzle will harden first on the mold surface. Subsequent hot resin that enters the mold will not blend well with the cooler layer and will pile up, forming noticeable lines. This problem can be addressed by changing the gate position or enlarging the gate to slow the flow speed. Another method is to install a tap gate.

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Appearance

Plastic at a relatively low temperature is injected from the nozzle during the initial stage of molding, upon coming into contact with the mold wall, this plastic becomes highly viscous and swirling takes place; furthermore, as hotter plastic is continuall y injected into the die, the original material is pushed deeper into the die and leaves flow marks. When the plastic temperature is low, the viscosity of the molten material is high, and this become higher in the case of plastic which has been injected into the die; consequently, the resistance to flow is large and jetting occurs. When the die temperature is low, the material injected into it will be rapidly cooled, and the corresponding increase in viscosity leads to the occurrence of this problem. When gates are small, the speed of plastic injected into the cavity will be relatively fast, and this leads to the occurrence of jetting in many cases. (Gate sectional area x flow speed = Fixed injection amount ) Molding conditions: Increase the temperature of the plastic to lower its viscosity. In the case of amorphous plastics, the id eal temperature of the die is between 20deg.C and 30deg.C lower than the plastic's thermal deformation temperature. It is also beneficial to reduce the injection speed. Dies.

Cause

Countermeasures

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4) Weld Line

Figure 11 : Weld Line The weld line is the place where the resin flow contacts the two halves of the mold. The line appears when the resin temperature is not high enough for the molted polyme to completely blend together. Eliminating the weld line altogether is difficult, so molds are designed to position the weld line where it will not show on the finished product and where it will not weaken the product.

5) Sink Mark

Figure 12 : Sink Marks

Figure 13 : Sink Mark Occur

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A sink mark is a depression in the molded product surface. This is one of the greatest causes for defects and most often occurs on thick ribs or other projecting parts. Sink marks happen when cooling resin loses some of its volume, and this shrinkage is not replenished. This volume reduction can also cause voids inside the plastic. It is important to supply sufficient packing pressure to fill in areas where volume has been reduced during resin cooling. Be sure that the wall thickness of the mold is uniform during the mold design stage.

Cause Injection pressure is low. Cooling time is short. Resin shrinks excessively during cooling. The mold temperature is high. Resin volume per shot is insufficient. Molded products are too thick.

Solution Increase injection pressure and time. Lower the mold temperature and lengthen the cooling time. Lower the cylinder temperature. Blend in an inorganic additive to the material to reduce shrinkage. Lower the mold temperature. Increase the resin measurement slightly. *Be careful not to induce flashing If the thickness occurs at the reinforced parts of the product, reduce the thickness and design ribs instead. Design the product thickness to be as uniform as possible and do not allow abrupt changes in thickness. Design the rib and boss to be as small and thin as possible. Increase the size so that pressure is delivered evenly throughout the mold. Position the gate where the mold is thick. Reduce the gate size. Increase the packing time.

The gate, sprue or runner are small. The gate position is improper. The gate is too big(when the resin flows back out of the cavity).

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5.0 DETERMINE THE COST SOLUTION As we know that cost is the most important role in any industrial machining. Injection molding that is the main process we discuss is highly cost in every industrial because of the mass usage of electrical supply and also human workers. So all the cost that have the factory store has spent is equivalent to half million per year. Including tax for the government, maintenance and etc. 5.1 Production Cost (Before improvement) DETAILS New Material Manufacturing Modify the plant layout Tools and Equipment Production equipment TOTAL 10,000,000 100,000,000 ESTIMATED COST (RM) 90,000,000 -

MODAL Expenses Modal

Working Modal (1 month)

Raw material purchase Workers salary Factory rental Electrical rental Building / machine maintenance TOTAL TOTAL (Expenses + Working)

700,000,000 60,000,000 9,000,000 10,000,000 779,000,00 879,000,000

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An improvement we can made by deducting all the not necessary things and cut the cost of not available electrical supply. Also, cut the working hours for the works that does not need their work if most of the time it was doing by a machine. It may have to be monitor by a person but it has not to be by too many person to monitoring one machine. So, by doing this we can save more cost per year or per month.

5.2

Production Cost (After improvement) MODAL DETAILS New Material Manufacturing Modify the plant layout Tools and equipment Production equipment TOTAL ESTIMATED COST (RM) 20,000,000 20,000,000 40,000,000

Expenses Modal

Working Modal (1 month)

Raw material purchase Workers salary Factory rental Electrical rental Building / machine maintenance TOTAL TOTAL (Expenses +Working)

400,000,000 60,000,000 7,000,000 5,000,000 472,000,000 512,000,000

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5.3 Statement of modal budget

= Total production cost before improvement Total production cost after improvement = RM 879,000,000 RM 512,000,000 = RM 367,000,000 5.4 Cost for material or tools condition Problem Solving Clamping Force Injection Machine Adjust the clamp force if the machine capacity does have enough clamp force. But, if there clamp is damaged, the clamp need to be replaced. RM318-RM 954 / Set

Cost Required -

6.0 CONCLUSION As a conclusion, after an improvement over the budget cost, we can see that we can save about half of the actual value before the improvement have been made. All this improvement is good for some company that has less demand for their product. Most of the machine that has in this factory is highly cost. Fujitsu also have to use a workers to complete most of the product and also to monitoring all the machine that does the job. So, highly recommendation is totally directed to any factory that did not have any big input and output so that it can reduced the cost of their spent. Lastly, every company in manufacturing industries having a lot of problem related to the product defect from product process. This defect comes from many factors which is material, manpower, machine maintenance and standard operation process like the above state. So, material selection is very important to make sure that the material is suitable for that product in order to avoid any problem or defect to the product.

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7.0 REFERENCE 1) 2) 3) 4) 5) 6) 7) 8) 9) [Link] [Link] [Link] [Link] Modul Teknologi Pembuatan. [Link] [Link] [Link] [Link]

10) [Link]

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