Research Article
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İstatistiksel Süreç Kontrolü ile Plastik Enjeksiyon ve Titreşim Kaynak Süreçlerinde Hataların Azaltılması

Year 2021, Volume 6, Issue 2, 7 - 18, 31.12.2021

Abstract

Bu çalışmanın amacı, plastik enjeksiyon kalıplama ve vibrasyon kaynağı ile imal edilen kondenser kurutucu su tanklarında görülen belirli bir kusuru azaltmaktır. Bu tanklarda karşılaşılan su sızıntısı sorununun istatistiksel süreç kontrol teknikleri ile en aza indirilmesi hedeflenmiştir. Öncelikle bu problemin maliyeti ortaya konularak su kaçağı problemi ve önemi belirlenmiştir. Problem tespit edildikten sonra imalat iş akışı verilmiştir. Ardından, su deposu sızıntısının olası nedenlerini gösteren neden-sonuç diyagramı oluşturulmuş ve kök nedenler ayrıntılı olarak tartışılmıştır. Daha sonra süreç kararlılığını incelemek için kontrol grafikleri oluşturulmuştur. Ek olarak, iyileştirme öncesi süreç yetenek analizi gerçekleştirilmiştir. Su sızıntısı sorununun temel nedenleri arasında hem enjeksiyon kalıplama hem de titreşim kaynak işlemlerinin olduğu belirlenmiştir. Bu nedenle yapılan iyileştirme çalışmaları arasında kalıp bakımı ve temizliği ile kaynak makinesinde özel fikstür kullanımı yer almıştır. İyileştirmeler yapıldıktan sonra son kontrol grafikleri oluşturulmuş ve süreç yeterlilik analizleri yeniden gerçekleştirilmiştir. Sonuçlar, iyileştirilmiş sürecin kontrol altında olduğunu ve süreç kapasitesinin önemli ölçüde arttığını ortaya koymuştur. Ayrıca yapılan iyileştirmelerin istatistiksel anlamlılığı ve önemi hipotez testleri ile doğrulanmıştır. İyileştirmeler sürdürülebilirlik için standartlaştırılmıştır. Son olarak, ek bir düzeltici faaliyet olarak, önceki manuel sistemin yerine yeni bir otomatik sızıntı test sistemi tasarlanmış ve kullanılmıştır. Bu iyileştirme aynı zamanda müşteriye sevk edilen hatalı su tankı miktarını da azaltmıştır.

References

  • [1] Desai, D. and Prajapati, B. N. (2017). Competitive advantage through Six Sigma at plastic injection molded parts manufacturing unit. International Journal of Lean Six Sigma, 8(4), 411-435. Doi: https://doi.org/10.1108/IJLSS-06-2016-0022
  • [2] Khavekar, R., Vasudevan, H. and Modi, B. (2017). A comparative analysis of Taguchi methodology and Shainin system DoE in the optimization of injection molding process parameters. In IOP Conference Series: Materials Science and Engineering (Vol. 225, No. 1, p. 012183). IOP Publishing.
  • [3] Maged, A., Haridy, S., Kaytbay, S. and Bhuiyan, N. (2019). Continuous improvement of injection moulding using Six Sigma: case study. International Journal of Industrial and Systems Engineering, 32(2), 243-266. Doi: https://doi.org/10.1504/IJISE.2019.10021839
  • [4] Vogtschmidt, S., Fiebig, I. and Schoeppner, V. (2020). Vibration welding of components with angled areas in the direction of vibration. Welding in the World, 64(11), 1843-1853. Doi: https://doi.org/10.1007/s40194-020-00964-6
  • [5] Patham, B. and Foss, P. H. (2011). Thermoplastic vibration welding: Review of process phenomenology and processing–structure–property interrelationships. Polymer Engineering & Science, 51(1), 1-22.
  • [6] Troughton, M. J. (2008). Handbook of plastics joining: a practical guide. William Andrew: Norwich, NY, USA. Doi: https://doi.org/10.1016/B978-0-8155-1581-4.50005-

Decreasing Defects in Plastic Injection Molding and Vibration Welding Processes Through Statistical Process Control

Year 2021, Volume 6, Issue 2, 7 - 18, 31.12.2021

Abstract

The goal of this study is to decrease a particular defect seen on condenser dryer water tanks, which are manufactured through plastic injection molding and vibration welding. Water leakage problem encountered on these tanks were aimed to be minimized through statistical process control techniques. Initially, the water leakage problem and its criticality was determined by presenting the cost of this problem. After determination of the problem, manufacturing workflow was provided. Next, cause-and-effect diagram presenting the potential causes of water tank leakage was created and the root causes were discussed in detail. Then, control charts were created to examine the process stability. In addition, initial process capability analysis was conducted through which poor capability was revealed. It was determined that both injection molding and vibration welding processes were among the root causes of water leakage problem. Therefore, improvement efforts made included mold maintenance and cleaning, and usage of custom fixtures on the welding machine. After improvements took place, final control charts were created and process capability analyses were re-conducted. Results revealed the fact that the improved molding process was in control and the process capability was enhanced dramatically. In addition, the significance of the improvements made were verified through hypothesis testing. The improvements were standardized for sustainability. Finally, as an additional remedial action, a new automated leakage testing system was designed and utilized as a replacement for the previous manual system. This action also decreased the amount of faulty water tanks that are shipped to the customer.

References

  • [1] Desai, D. and Prajapati, B. N. (2017). Competitive advantage through Six Sigma at plastic injection molded parts manufacturing unit. International Journal of Lean Six Sigma, 8(4), 411-435. Doi: https://doi.org/10.1108/IJLSS-06-2016-0022
  • [2] Khavekar, R., Vasudevan, H. and Modi, B. (2017). A comparative analysis of Taguchi methodology and Shainin system DoE in the optimization of injection molding process parameters. In IOP Conference Series: Materials Science and Engineering (Vol. 225, No. 1, p. 012183). IOP Publishing.
  • [3] Maged, A., Haridy, S., Kaytbay, S. and Bhuiyan, N. (2019). Continuous improvement of injection moulding using Six Sigma: case study. International Journal of Industrial and Systems Engineering, 32(2), 243-266. Doi: https://doi.org/10.1504/IJISE.2019.10021839
  • [4] Vogtschmidt, S., Fiebig, I. and Schoeppner, V. (2020). Vibration welding of components with angled areas in the direction of vibration. Welding in the World, 64(11), 1843-1853. Doi: https://doi.org/10.1007/s40194-020-00964-6
  • [5] Patham, B. and Foss, P. H. (2011). Thermoplastic vibration welding: Review of process phenomenology and processing–structure–property interrelationships. Polymer Engineering & Science, 51(1), 1-22.
  • [6] Troughton, M. J. (2008). Handbook of plastics joining: a practical guide. William Andrew: Norwich, NY, USA. Doi: https://doi.org/10.1016/B978-0-8155-1581-4.50005-

Details

Primary Language English
Subjects Engineering
Journal Section Research Article
Authors

Meryem ULUSKAN (Primary Author)
ESKISEHIR OSMANGAZI UNIVERSITY
0000-0003-1287-8286
Türkiye

Publication Date December 31, 2021
Published in Issue Year 2021, Volume 6, Issue 2

Cite

Bibtex @research article { ojn1019741, journal = {Open Journal of Nano}, issn = {}, eissn = {2147-0081}, address = {Sakarya Üniversitesi Fatih Mah. Eşit Sok. No:7/A -11 54580 - Arifiye / SAKARYA}, publisher = {Mustafa CAN}, year = {2021}, volume = {6}, pages = {7 - 18}, doi = {}, title = {Decreasing Defects in Plastic Injection Molding and Vibration Welding Processes Through Statistical Process Control}, key = {cite}, author = {Uluskan, Meryem} }
APA Uluskan, M. (2021). Decreasing Defects in Plastic Injection Molding and Vibration Welding Processes Through Statistical Process Control . Open Journal of Nano , 6 (2) , 7-18 . Retrieved from https://dergipark.org.tr/en/pub/ojn/issue/65078/1019741
MLA Uluskan, M. "Decreasing Defects in Plastic Injection Molding and Vibration Welding Processes Through Statistical Process Control" . Open Journal of Nano 6 (2021 ): 7-18 <https://dergipark.org.tr/en/pub/ojn/issue/65078/1019741>
Chicago Uluskan, M. "Decreasing Defects in Plastic Injection Molding and Vibration Welding Processes Through Statistical Process Control". Open Journal of Nano 6 (2021 ): 7-18
RIS TY - JOUR T1 - Decreasing Defects in Plastic Injection Molding and Vibration Welding Processes Through Statistical Process Control AU - Meryem Uluskan Y1 - 2021 PY - 2021 N1 - DO - T2 - Open Journal of Nano JF - Journal JO - JOR SP - 7 EP - 18 VL - 6 IS - 2 SN - -2147-0081 M3 - UR - Y2 - 2021 ER -
EndNote %0 Open Journal of Nano Decreasing Defects in Plastic Injection Molding and Vibration Welding Processes Through Statistical Process Control %A Meryem Uluskan %T Decreasing Defects in Plastic Injection Molding and Vibration Welding Processes Through Statistical Process Control %D 2021 %J Open Journal of Nano %P -2147-0081 %V 6 %N 2 %R %U
ISNAD Uluskan, Meryem . "Decreasing Defects in Plastic Injection Molding and Vibration Welding Processes Through Statistical Process Control". Open Journal of Nano 6 / 2 (December 2021): 7-18 .
AMA Uluskan M. Decreasing Defects in Plastic Injection Molding and Vibration Welding Processes Through Statistical Process Control. ojn. 2021; 6(2): 7-18.
Vancouver Uluskan M. Decreasing Defects in Plastic Injection Molding and Vibration Welding Processes Through Statistical Process Control. Open Journal of Nano. 2021; 6(2): 7-18.
IEEE M. Uluskan , "Decreasing Defects in Plastic Injection Molding and Vibration Welding Processes Through Statistical Process Control", Open Journal of Nano, vol. 6, no. 2, pp. 7-18, Dec. 2021

ISSN:2147-0081
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