The Hybrid Pareto Chart and FMEA methodology to Reduce Various Defects in Injection Molding Process

Abstract

Over the last two decades, the increased in industrialization, a lot of innovations, variety and volume leads to the improved standard of living associated with the number of advantages to the peoples due to the development of new manufacturing techniques. The industrialists are struggling a lot to increase the overall equipment Effectiveness (OEE) to reducing production time, unplanned stops due to equipment failures and material shortages, Quality Loss due to   defective pieces etc,. Dimensional and quality changes are the most important troubles in production of PVC material using injection molding process. The aim of this study is to identify the root cause of the defected items and to generate a solution to reduce the percentage of defect by using quality control (QC) tools:  Pareto Chart and Failure Mode and Effects Analysis (FMEA) are used for the continuous improvement and to reduce defects while manufacturing the PVS sole using injection molding process. Risk Priority Number (RPN) is obtained from past record, so as to hit upon the exact problem and the necessary measures are suggested for the future.

Keywords- Quality Loss; Defects, Pareto Chart; Failure Mode and Effects Analysis (FMEA); PVS sole, Injection molding process; Risk Priority Number (RPN)