●
Non union shop
●
Shutdown processors per shift = 6
●
Rust preventative is applied
during shutdown to prevent molds from degrading. Requires more waste material
during start up, but mold refinishing is more expensive and time consuming
●
Ed is responsible for about 30
machines
●
2-950 is hydraulic and needs to be
run by hand when purging
●
3-300 is servo driven and can be
run automatically
●
2-950 has a chiller that needs to
be adjusted before shutdown
●
330lbs drier, 100 lbs/hr = 3 hr
dry time
●
Beads from the bottom of the drier
that may have collected moisture over a shutdown are emptied from the drier and
placed back in the material container and run through the drier.
○
Drier is less efficient at the
bottom, so beads at the bottom may have absorbed moisture when the drier sits.
●
Machines have a 5 shot rule, if
more than 5 shots do not pass then technicians and supervisors are alerted
●
Initial purge it required to
finish cleaning out purgex and marlex because machine will not run if hopper is
empty, leaving material in the barrel.
●
3-300 has a heated manifold
○
Mold needs to be flushed too
because the hot manifold has plastic in it
○
1st shot is a short shot
○
Sheen on initial parts is from the
rust preventative applied during shutdown
○
The first 5 shots are usually
ignored and scrapped
○
8 shots to first good part, 15 min
■ 1 partial, 7 complete
●
2 locations of purge material
barrels, one set in the front and one set in the back. 1 barrel of each type
●
2-950 has a chilled manifold
○
Marlex used on start up to finish
purging burnt PVC from barrel
○
3 buckets were used until good,
anywhere from 1-8 buckets can be used depending on how well it was cleaned on
Friday
■ Carbon forms in the machine and can break off at anytime, requiring
more purge material.
○
A lot of the start / stop in the
purging process is based off operator judgement / experience and is heavily
visual
○
Start machine with a full shot
■ 8 shots until a good part, about 40 min
3-300 (Nylon)
-
From feeder off to last good part
- 27.08.04
-
Purge material in to clean barrel
- 35.50.09
-
Difference = 8.42.05
Solution
Journal
ASPM Notes
9/6 125 words
We went last Friday to
the ASPM factory to see how all the operators do their work also to see how the
3-300 and 2-950 shutdown and I was recording everything with my phone and at
that day we have met with the client to walk with us and let us meet with the
operators
We
went to the ASPM factory last Friday. We saw how operators worked and the
shutdown of 3-300 and 2-950. I recorded these activities on my phone. Operators
in the production line facilitated manufacturing and assemblage of machines,
products, and food stuff. Production line operators were hired by manufacturing
and packaging factories to work in flexible full time schedule. The production
line workers were the main components of the factory and they reported their
work to the floor supervisor. The production line operators performed the same
task everyday and, they were the laborers who maintained the standard of
products being manufactured at the factory. During a shutdown, the job and
duties in the production line shifted.
The supervisors for maintenance were moved to the area of critical work.
The engineers wee responsible to work as “owners’ representative”. The
engineers managed contract work. Planners had a schedule of job duties. The
critical paths were scheduled and progress was reported on daily basis. During
shutdowns, there was unexpected work load.
9/8 125 Words
We went last Sunday to
the ASPM factory to see how all the operators work and also to see how the
3-300 and 2-950 start-up and also, I was recording everything with my phone and
also the Client was walking with us
On
Sunday, we went to see how all operators worked and client was walking with
us. The operators were responsible for
plant operations. They monitored and solved problems related to equipments.
They loaded and unloaded material from railcars, and so on. They were
responsible for housekeeping. The environment and safety standards were
maintained by the operators. The operators designed, conceptualized, and
implemented the project and showed improvements according to the demands of
clients. The client was communicating with operators regarding the nature of
product and relating the products to his demands. The process operators
overviewed the process of manufacturing. They made sure that project is free of
flaws. The process operators make sure that the quality and standard of
products is maintained. I made the video
to present in the class.
9/10 (Day 5) 75 words
Our Advisor gave us a
presentation
The
advisor gave us a presentation regarding all service plastic molding (ASPM). It
was explained that APSM manufactures injection molding. The injection molding
process involves innovation and quality. The factory specializes in
manufacturing of plastic products. There is assemblage of plastic products.
There are more than ninety presses from 55 to 1,100 weights in tons. The
factory is committed to provide excellence in all the manufactured goods. The
factory has latest technology related to injection molding and complex
processes and assemblies. The students
need to visit this factory, and narrate their experiences to the class in form
of formal presentation and indulge in group discussions to make their knowledge
more clearly to themselves.
Day5 - Post-Proposal
(1).ppt
Also
we have met all together to collect all the date from our last two visits to
the factory. We were a group of students who visited ASPM factory. We saw
shutdown of operations and their starting up. Throughout our visit to the
factory, the client was walking with us and sharing tiny mini details to remove
any ambiguity we had in our minds.
9/12 125 words
In that class we had a
Conference Call with the client to ask him some questions and also we was
working on our weekly report in it was not individual cuz we didn’t do a lot of
individual my Advisor told us that we can submit it as a group in this time
We
had a conference call with the client to ask him some questions. We asked him
about the injection molding expertise. The client told that the factory
manufactures thin wall injection, gas assist, vacuum assist, long glass fiber,
hot oil, sequential gate control, insert molding, two shot molding, in mold
decorations, and so on. The client explained us uses of injection molding.
Packaging bottle caps, wire spools, pocket comb, toys, small tables, mechanical
parts, and many other useful products are made from injection molding. The
client had a pleasant working experience with the factory. The standard of the
products was same since 20 years. The
client shared how the factory keeps up with tough deadlines and schedules. The
client was very cooperating and answered all of our questions.
Project Progress
Report 9.13.pdf
And
also we were working on the Variables
There
are two variables, independent and dependent. The independent variable is the
production in a factory. This is under control and can be manipulated according
to the benefit of the company or client. The independent variable influences
the outcomes negative or positive. We have seen how the quality of products
satisfied the client and profitable for factory and workers. A variable is simply something which can be
changed or modified. The dependent
variable is of key interest for the researcher or visitors. We visited the
factory to search for dependent variable. We got to know that the dependent
variable is the product, the independent variable is the standard and demand in
manufacturing. The demands affect dependent variable i.e. product.
9/17 125 words
In
that date we had our first presentation with our Advisors
Update 1 ASPM
Project.pdf
And my part was the
problems and the( cause and effect ) And they gave us some notes that we need
to be specifics and we need to put all the date that we have and some pic of
the Factory
My
part is cause and effect. In cause and effect relationship, we study the links
between events and how events lead to outcomes. In the factory, we have seen
that the equipments shut down were events and how job roles changed as a result
of breakdown is effect. This is instance of cause and effect. In a factory, the
client placed an order, the factory made products accordingly. The factory
received more orders. This event i.e. manufacturing of goods, led to more
orders and profits i.e. effect. A visit
to plastic factory was a cause or event which enhanced our knowledge regarding
manufactured goods and clients’ experience, this is effect. The cause and effect simply makes a
relationship among events and their effects or consequences.
9/18 75 words
In this day we have met
all together at the library from 8:00PM to 10:00 to analyze all the videos
recording that we already have so in next class we have another Conference Call
with the client
We
met in the library to see all the videos from 8:00 pm to 10:00 pm. We had
another conference call with the client. There were some loop holes and
ambiguities regarding which we needed to call the client. The client answered
all our queries. There was some confusion related to the process of manufacturing.
The client explained that operations manager supervises that the products are
made according to demands of clients and standards of the factory.
9/19 75 words
We have met all together
to finish analyzing the videos and get ready for Conference Call with the
client but he was busy so we moved it to 9/24/19
The
client was busy on 9/18, so we scheduled a phone call on 9/19. There were some
demands of the clients which he used to make related to the product. The client
was explaining the specific demands he used to forward to the factory. The
factory specifically designed those products for him. The client explained us
the machinery used in manufacturing of his products. The client placed huge
orders in the factory and the factory valued him.
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