Salee Company Limited suffers this setback. Therefore, it should align itself in a position to maximize profits by looking in to the ways of reducing the loss. Mr. Somsak Pruksawan of the Salee Industry Public Company Limited admits that every organization, large or small businesses suffers various types of obstacle when performing businesses. Their problem is the management of the waste and the plastic defects. The management of the company notes that the company faces various difficulties. These problems range from the upstream of supply chain processes to the end customers or the consumers of their products. The material cost varies with the mass of material that that facilitates the process and the price unit of that material. The heaviness of material is vividly a result of the proportion volume and material density. However, the fraction's maximum wall widths play a role (Lindsay, 2010, p.57).
The weight of raw material that fits in this research includes the material that fills the compartments with the mold. The size of those channels, and hence the amount of material, largely changes along with the thickness of the part. In an attempt, to check the financial spending for any company and evaluating how valuable it is to assess the costs it is worth categorizing the production cost in to various subgroups. Pareto rule acknowledges that to check spending then an individual should rearrange his resources and the expenditure to determine the appropriate balances. Noting of the 20% of the investment that control or consume 80% of resources is vital (Goodship & Rapra Technology Limited, 2010, p.38). Production cost and the tooling cost are the most widespread expenditures on the production of the plastic products. The companies calculate the production cost in terms of the hourly rate. This is possible in the analysis of the cycle time. The calculation in the hourly rate is usually proportional to the magnitude of the injection-molding machine applied.
The amount of the material passing through the injection molding machines gets the analysis in considering the tonnage of the fastening force they offer. The products lost in wastes and defects, in tonnage amount to 80% of the company loss. However, the clamping force varies by change in the projected expanse of the fraction and the stress with which the substance gets the injection. The cycle time divides into the injection session cooling duration and resetting time. In reducing these factors, the production expense lowers (Gordon, 2010, p.37). However, the injection time decreases in reducing the utmost wall thickness of the fraction and section of volume (Groover, 2010, p.30). The numerous thermodynamic qualities of the material influence the cooling time. The resetting time clings on the machine size, in addition to part magnitude. Noting from the skills in the plastic injection molding processes, Mr. Somsak states that in the beginning when they started doing the business, they did not have initial capital to invest in the fully automatic injection machines. These that workforce were the chief sources that they applied in their operation processes. The defects are not easily controllable by human intervention noting that the operation involves an enormous amount of heat releases. He adds that it was unfortunate the company had challenges originating from human errors in the production processes.
There are various errors that occur from human such as incomplete in melting of plastic ball before inject into the mould (Malloy, 2009, p.90). In addition, the material deficiencies in molding machine barrel heating duration causes a timely manner suitable to the mould melt. Moreover, the workers release the injection machine before the plastic part is cool and set. It is in the form of the die. This creates the defects and losses during the production activities (Osswald et al., 2009, p.97). Later, the company has to improve the operation process by investing a vast amount of investments in the high technology machines. Pareto rule suggests that works input determined the success of the 80% of the profits accruable from the manufacturing process. The interview with production managers and assistant production manager of sale reveals that both waste and defects are a considerable problem that an individual cannot eliminate from the production processes. He contends that their company had invested in high technology automatic machines (Osswald et al., 2009, p.90). They argue that defects may occur from human error or even the error from the injection machines.
Salee Industry Public Company Limited has set up the quality control division in order to check the quality of the parts before submitting the orders to their valuable customers. He argues that initiation of the control unit results in fluctuation and falling for wastes that emanated from the company.
The analysis of the defects and checking an appropriate remedy relies on the evaluation of the nature of the product defects and the wastes (Malloy, 2009, p.98).The roles that customers and the manufacturers play in the process of production are fundamental in determining the effect of the defects and wastes in the production process. The management of sale provides for the customer to order plastic ball or plastic sheet that use in production by himself or herself. They may choose to let Salee procure raw materials from own suppliers. The customer suggests type and quality of raw material that they are required to use in production. They explain that at present, the proportion of raw materials supplied by customers and Salee is around 30:70 of total raw materials applied in the production. They import approximately 90% of the total material from Thai and Japanese suppliers who have manufactured in Thailand Muccio, 2009, p.79). The lose emanating from the production reads malice to the customer if suppose he bought the material. Avery in his book Injection molding alternatives: A guide for designers and product engineers contends that Injection Molding process is a chief processes for manufacturing plastics items. He acknowledges that the process depends on the use of an injection-molding machine.
The operator pours the raw plastic material into plastic granules (Bryce, 2009, p.49). Heat application takes place melting the substances. A reciprocating screw injects the semi-liquid material in the injection molding machine vacuum Muccio, 2009, p.78). The quality control process for the injection mode of the production is essential in regulating the wastes. It aids in the checking of the expanse of the defects derived from the production. Training of the workforce is fundamental in achieving the limits the y should achieve in their work (Rosato & Plastics Institute of America, 2010, p.123). Some workers negligently decide to work low beyond their expected capacity leading to poor and undesirable quality of work. The quality control unit helps in the management of the Sink Marks, Gas marks or burning, Flash, Short shots, Knit Lines as known as weld lines, Splay and Flow marks (Lindsay, 2010, p.56). The solidification of the outer skin facilitates the formation of the sinks .it is common that the inner fraction of the material remains molten or viscous. This process of unregulated cooling leading to the sink marks on the surface of the material products. Campbell explains the best ways of the checking the problem ensuring the consistency on the wall thickness of the product manufactured. Adjustment of the molding parameters is indispensable in the preventing the proceeding of the defects. Gas marks on the materials emerges from the effects of the air on the vacuum cavity of the molder (Goodship, 2010, p.50). Lack of spaces for the escape the air prompts the formation of the gas marks on the products. The creation of the vents in the mold facilitates the regulation of the gas marks. However, the adjustment of the screw speed and its alteration reduces the burning of the materials. The flashing problem arises when dual halves of molds are not in contact together (Packham, 2010, p.40).
To achieve the vital parameter of the products the manufacturer should push the sides together. The regulation of this problem is achievable in t he efficient measuring and control of the tonnage. The proficient design of the mold is vital in the elimination of this challenge (Heissing, 2011, p.43). Campbell notes that some materials flash easily than other materials. This usually happens irrespective of the pressing of the mold. Poor flow of the molding materials in to the cavity prompts the formation of the Short shots (Rosato & Plastics Institute of America, 2010, p.40). Miniature flow of the materials prompts the poor filling of the mold. The manufacturer of the plastic products regulates the problem in controlling the injection mold parameters. Knit Lines arises if part of the mold has a hole. This facilitates the flow of the materials inside the hole facilitating the meeting of the two sides of the material mould. Reduction of this problem is achievable in adjusting processing parameters like the injection pace and mold hotness. Splay forms if the bubbles flow along with the flow on the surface in the plastic injection molding progression. This…