Management of Plastic Injection Processes: A Case Study of Electric Lamp Manufacturing

Abstract

The product quality inspection is processes of inspecting and controlling quality of the product by specifying waste controlling standards for controlling waste proportion. When wastes exceeded the waste controlling standard, the inefficient process in production must be improved. This research collected data on 2 product groups which are clear plastic products with waste controlling standard of less than 3 and coloured plastic products with waste controlling standard of less than 7%. Both groups are the main production line of the company. The researcher applied 7 Wastes Theory and Quality Control Tools for data collection then analysed the root causes of the waste that occurring in the production line in order to highlight the actual waste proportion in the production line as well as set the policy for encountering excess waste by applying ECRS concept, which consisted of Eliminate, Combine, Rearrange, and Simplify, as a production processes improving guideline. After improving the production processes, the machine set up time in chasing processes reduced from average of 25 minutes to 15 minutes. Moreover, after rearranging injection moulding machines into each product line, the waste in the injection moulding was reduced by 45.08 in clear plastic product and 60.17% in general products which resulting in the total waste proportion was being within the waste controlling standard limit.