Analysis on the current status of production efficiency of injection molding products

1.1 Analysis of production process and key links

In the process of improving the production efficiency of injection molded products, an in-depth analysis of the production process and key links is a crucial first step. The production process of injection molded products usually includes raw material preparation, mold installation, injection molding, cooling and demoulding, post-processing and quality inspection. Among them, mold installation and injection molding are the core links, which have a decisive impact on the overall production efficiency.

Take mold installation as an example. Traditionally, mold replacement often takes several hours or even longer, which not only increases downtime but also reduces production efficiency. According to industry statistics, mold replacement time accounts for 20%-30% of the entire production cycle, which is an important bottleneck in improving production efficiency. Therefore, by introducing the quick mold change system (SMED), the mold change time can be significantly shortened and production flexibility improved. After a well-known injection molding company implemented rapid mold change, the mold change time was shortened from an average of 4 hours to 30 minutes, and the production efficiency increased by nearly 30%.

The injection molding link is equally critical, as it directly determines the quality and output of the product. In this link, factors such as mold design, injection molding machine performance, and process parameter settings will have a significant impact on production efficiency. For example, by using advanced hot runner technology, waste production can be reduced, material utilization can be improved, and the molding cycle can be shortened. According to research, the molding cycle of injection molded products using hot runner technology can be shortened by 10%-20%, and the material utilization rate can be increased by 5%-10%.

In addition, the cooling demoulding and post-processing links in the production process cannot be ignored. Optimizing the design of the cooling system and using efficient cooling media and cooling methods can speed up product cooling and shorten demoulding time. The post-processing process includes deburring, trimming, assembly and other steps. By introducing automated equipment and optimizing the operation process, the processing speed and consistency can be further improved. As management guru Peter Drucker said: "Efficiency is the ability to do things well, not the appearance of being busy." In the production of injection molded products, it is through continuous optimization of the production process and key links that we can truly achieve production efficiency. Significant improvement.

1.2 Production efficiency evaluation indicators and methods

In the evaluation of injection molding product production efficiency, we use a series of scientific and comprehensive indicators and methods to ensure the accuracy and effectiveness of the evaluation. First, we focus on "output per unit time", that is, the number of injection molded products per hour or per day. By comparing historical data with current production data, we found that after implementing the new production process optimization, the output per unit time increased significantly, from the original 5,000 pieces per day to 6,500 pieces, with a growth rate of up to 30%. This data directly reflects the significant improvement in production efficiency.

Secondly, we used the key indicator "equipment utilization", which reflects the effective working time of the injection molding machine in the production process. By introducing an advanced production management system, we have achieved real-time monitoring and scheduling of equipment status, increasing equipment utilization from the original 75% to 90%. This improvement not only reduces equipment idle time, but also further improves overall production efficiency.

In addition, we also use "defective rate" as an important dimension to evaluate production efficiency. The reduction in the defective rate not only means an improvement in product quality, but also indirectly reflects an improvement in production efficiency. By introducing automated inspection and quality control processes, our defective rate dropped from the original 3% to 1%. This significant improvement not only improved customer satisfaction, but also reduced additional costs due to rework and scrap processing.

In terms of evaluation methods, we combine quantitative analysis with qualitative analysis. Quantitative analysis mainly collects and processes production data and uses statistical methods to conduct trend analysis and comparative studies, while qualitative analysis focuses on in-depth understanding and evaluation of production processes, employee skills, equipment status, etc. Through the organic combination of these two methods, we can evaluate the production efficiency of injection molded products more comprehensively and accurately, and provide strong support for subsequent improvements and optimizations.

As management guru Peter Drucker said: "If you can't measure it, you can't manage it." It is through this series of scientific and comprehensive production efficiency evaluation indicators and methods that we have achieved effective measurement of the production efficiency of injection molding products. management and continuous improvement.

1.3 Analysis of typical production efficiency problems and causes

In the analysis of the current situation of injection molding product production efficiency, we have to face up to a series of typical production efficiency problems and the reasons behind them. For example, mold replacement is frequent and time-consuming, which is one of the key factors restricting the improvement of production efficiency. According to industry statistics, the average traditional mold replacement process can take several hours or even longer, which not only increases downtime but also reduces overall production capacity. In response to this problem, in-depth analysis found that the main reasons are low standardization of mold design, cumbersome mold replacement process, and uneven skill levels of operators. As management guru Peter Drucker said: "Efficiency is the ability to do things well, not the ability to do more things." Therefore, the key to improving the efficiency of mold replacement is to optimize the mold design, simplify the mold replacement process and strengthen personnel training.

Another typical problem is insufficient automation in the production process. In many injection molding companies, manual operations still dominate, which not only increases labor costs, but also easily leads to production errors and low efficiency due to human factors. By introducing automated equipment, such as robots, automated conveyor lines, etc., manual intervention can be significantly reduced and production accuracy and efficiency improved. For example, after an injection molding company implemented an automated production line transformation, its production efficiency increased by 30%, and its product defect rate decreased by 20%. This case fully proves the important role of automation technology in improving injection molding production efficiency.

In addition, the management and analysis of production data are also important factors affecting production efficiency. Many injection molding companies lack real-time and accurate data support during the production process, resulting in delayed decision-making and waste of resources. By introducing intelligent management systems, such as MES (Manufacturing Execution System), ERP (Enterprise Resource Planning), etc., real-time monitoring and analysis of production data can be achieved, providing strong support for production decision-making. For example, a company conducted in-depth mining of production data through an intelligent management system and discovered that there was a bottleneck problem in a certain process. It then successfully solved the problem by adjusting process parameters and resource allocation, and production efficiency was significantly improved.

To sum up, improving the production efficiency of injection molded products requires starting from many aspects, including mold optimization, automation transformation, intelligent management, etc. Based on the analysis of typical production efficiency problems and their causes, we can take targeted measures and strategies to achieve an overall improvement in production efficiency. At the same time, we should also pay attention to the development of new technologies and new processes, constantly introduce innovative elements, and promote the development of injection molding production in a more efficient and smarter direction.