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Current Online Topic: IMPLEMENTING NEW TECHNOLOGY

Implementing New Technology
IMM 09/01

We're integrating scientific- or decoupled- molding into our operation. Technically, this has not been a problem, but we're getting resistance from some of our veteran employees who think the process is a gimmick and won't work. Their pessimism is starting to impede our efforts to implement the technology. Has anyone else had this or a similar problem implementing new technology, and how did you get through it?
We use scientific (decoupled) molding techniques on a daily basis and they are incorporated into technician training. The scientific method is not a gimmick as it properly defines the molding process. I have found people to be pretty receptive to using scientific methods once they understand what is being accomplished (i.e., defining the process using the four basic plastic variables). It is still necessary to understand the interrelationship of the machine controls and the four basic plastic variables. Further, it must be properly applied; otherwise, the result will be disappointing.

Separating mold filling from packing allows processors to maintain more consistent mold fillings, isolate fill for troubleshooting purposes, use the full performance of the machine, and make the best use of modern machine controls. Scientific molding also allows more accurate duplication of process from run to run and machine to machine.- B. Tutmark, GM Nameplate, Oregon Div., Beaverton, OR, (503) 350-2984, bradt@gmnamplate.com.

This is the second question dealing with scientific molding and implementation within recent months. I held off answering both because, as some of you know, I tend to get excited about this issue. Well, I have counter to 100 and I still see red! But these are real issues and good questions. Folks, you do not have a choice. Scientific molding is based on the laws of physics and chemistry and you cannot violate these laws. Trying to, wastes money and and there are a lot of people who have lost or changed jobs because of this.

For example, it is plastic pressure that determines a part's dimensions, not hydraulic pressure. A uniform nominal wall is the first rule of part design: A section of a plastic part that is 3mm thick will stay hot longer than a neighboring 1.5-mm section. If molding a semicrystalline, high-shrink resin you are going to have differential shrinkage (stresses and distortion). To duplicate a process you must duplicate the plastic variables, not machine parameters. Simply because the existing path is easier (molding based on machine variables) does not mean it is the correct path to take.

How much molding business have Microsoft, Hewlett-Packard, Xerox, and others shipped out of this country? Why? Molding is manufacturing; it supports the service industry. Without manufacturing there will be no need for service! If you want to keep your job or be able to get one, then we better be internationally competitive or we will lose. - J. Bozzelli, IM Solutions, (989) 832-2424.