Welcome to our deep dive into injection molding and how to reduce costs.
Yeah.
You sent over a whole bunch of articles and notes for us to look at. So we're going to try and like boil it down into some real key takeaways for you about how to make these parts that you want to make awesome, but also affordable.
Absolutely.
And I think this will be interesting even if you're not directly involved in manufacturing, just to kind of get a peek behind the curtain.
Yeah.
And understand what are some of the things that go into making products that are plastic.
Yeah. And the things people don't think about. Right. Like that go into making something efficient.
Like all the hidden costs.
Yeah.
So let's imagine that you're kicking off a project and you need to get some parts made. Maybe it's a brand new product you're developing. Where do we even begin when we think about cost reduction?
I think it all starts with the mold.
Oh, the mold.
Oh, yeah. The. The mold design itself has a huge impact on the ultimate cost of production.
Right.
It's like building a house. You know, if you don't get the foundation right, everything else becomes more difficult and expensive.
Got it. Okay. Yeah, that makes perfect sense.
Right.
So when we think about mold design, what. What are some of the things within that that really move the needle on cost?
One of the biggest factors is the number of cavities in the mold.
Cavities. Okay.
Yeah. So this refers to how many parts can be produced with each injection cycle.
Okay.
So for example, one of your articles talks about, you know, molds for like bottle paps that have like dozens of cavities in them.
Oh, wow.
So they can produce huge numbers of caps with every cycle.
Okay.
And that's really great for high volume production because it, you know, dramatically reduces the cost per unit.
Right. So it's like if you want to make a single cup of coffee, you could use a little single serve pod.
Yeah.
But if you have a whole dinner party coming over, you're going to want to use a big carafe.
Exactly. Yeah. It's about matching the tool to.
Right. Choosing the right tool for the job.
Yeah. To the output you need.
Okay.
But it's not always as simple as just like cranking up the number of cavities. You know, the complexity and size of the part also come into play. So for example, your notes mentioned a project involving a complex housing for some kind of electronic device. And in a case like that, a mold with just one or two. Two cavities might be necessary.
Okay. So that would obviously Affect the cost per unit.
Yeah, that's right.
Because you're making fewer. Yeah.
You're producing fewer parts per cycle. So your per unit cost is going to be higher. Right. And then beyond just the number of cavities, we also need to think about the design of the mold structure itself. You know, so how all those cavities are laid out and connected. One of your articles highlights a case study where they were able to simplify a mold structure by eliminating some unnecessary components. And this not only saved on material costs, but also made maintenance easier and faster.
So streamlining is kind of a key.
Streamlining and simplification are really key themes here.
Got it. And speaking of simplification, one of the articles mentioned something about standardizing components like ejector pins.
Yeah. Yes.
I don't even know what that is.
So ejector pins are these little mechanisms that push the finished part out of the mold. And the idea is if you can use standard sizes for these instead of custom ones.
Got it.
It means that you can replace them quickly and easily during maintenance. You don't need to hunt down specialized parts or wait for custom orders. So it can really save time and money.
So it's like if every electronic device just used a USB C charger.
Exactly.
That would make everyone's life easier.
It's like having a universal remote control for all your gadgets.
Right.
Instead of having a different one for every single thing.
Yes. Much simpler. Okay, so we've got the mold design down. Now what's the next big cost factor?
Well, once you've got your mold figured out, you need to think about the material you're gonna be using.
Okay.
Choosing the right material is critical, and it's about more than just the price per pound.
Okay, so what are some of the things we need to be thinking about when we're selecting materials?
One of the most important is the balance between performance and cost. Okay, so your notes mention the use of general purpose plastics like polypropylene for some projects. Okay. These are generally more affordable than the high performance engineering plastics.
Okay.
But they may not be suitable for every application.
Sure. So I guess it's like if you want a T shirt, you could get a simple cotton T shirt.
Right.
But if you're gonna go for a run, you might want one of those special sweat wicking materials.
Yeah. You need something more specialized.
Yeah. Okay.
Yeah, that's a good analogy.
So different materials for different jobs.
Exactly. But even within the categories of general purpose and engineering plastics, there are many different options with varying properties.
Oh, wow. So it's not that simple.
Yeah.
Okay.
So you really need to understand the specific requirements of your application.
Okay.
For example, some plastics are better suited for high temperatures.
Got it.
While others are more impact resistant.
Okay.
So again, it's about choosing the right tool for the job.
Right.
You wouldn't use a hammer to screw in a screw. And you wouldn't use a delicate material for a part that needs to withstand a lot of stress.
Okay, that makes sense.
And of course, we also have to factor in the actual cost of the material itself. You know, different plastics have different price points, but it's not just about the initial purchase price. You also need to consider things like waste and scrap rates.
Okay.
Some materials are more prone to defects, which can drive up costs.
So thinking about the entire life cycle of the material.
Precisely. Yeah. From procurement to processing to disposal.
Got it. And that brings up something else that I was curious about.
Okay.
Which is how do suppliers play a role in all of this?
Yeah, suppliers are a huge part of the equation. You know, a strong relationship with your suppliers can open up opportunities for better pricing and terms. So, for example, negotiating long term contracts or buying in bulk can lead to significant savings.
Okay.
It's like having a VIP membership at your favorite store.
You know, you get the special deals.
You get access to exclusive deals and discounts.
Right.
And it goes beyond just pricing. A good supplier can also be a valuable resource for technical expertise and support.
Okay.
You know, they can help you choose the right materials, optimize your process, and even troubleshoot problems that arise.
This is really a partnership.
Exactly. It's a two way street.
Okay.
And one of your articles highlights a really fascinating example of a company that partnered with their supplier.
Oh, wow.
To set up a system for recycling marginal waste.
Recycling waste.
Yeah. So in this case, how does that save money? They were able to reprocess and reuse some of the plastic that didn't meet their strict quality standards. Oh, okay. So this meant that they didn't have to purchase as much virgin material.
Got it.
Which saved them money and reduced their environmental impact.
So they're basically taking something that would have been thrown away and turning it into a valuable resource.
Trash into treasure.
That's awesome.
Exactly. And it's a great example of how thinking outside the box can lead to both cost savings and environmental benefits.
Okay, so we've covered mold design, we've covered materials.
Yeah.
What's next on our cost reduction checklist?
Let's talk about the injection molding process itself.
All right. Yeah, we'll dive into that after A quick break.
So the injection molding process itself, there's a lot you can do.
Yeah. It seems like there are a lot of moving parts. Literally.
There are. Yeah. A lot of variables that you can tweak and adjust.
So where do we even begin?
Well, think of it like a recipe.
Right.
I've got your ingredients. You know, the mold and the material.
Right.
And now you need to combine them in the right way at the right temperature for the right amount of time to create that perfect dish. Or in this case, the perfect part.
All right, so temperature and pressure, I imagine those are key things.
Absolutely. Right. Temperature and pressure are crucial.
Okay.
One of your articles goes into the science behind this. You know, different plastics have different melting points, they have different viscosities, meaning they flow differently at different temperatures.
Okay.
So getting the temperature just right ensures that the material fills the mold completely and evenly without degrading or burning.
And pressure, I imagine, makes sure it gets into all the.
Exactly.
Yeah. You need enough pressure to force that molten plastic into every corner of the mold.
Right.
But too much pressure can damage the mold or create defects in the part.
Got it.
So finding that sweet spot for both temperature and pressure is a dance.
It's really crucial.
Yeah. Okay. And speaking of efficiency, I saw in your notes something called smed.
Ah, yes, smed. Single minute exchange of dye.
Yeah.
It's a fantastic technique borrowed from Lean Manufacturing. It basically focuses on minimizing the time it takes to switch out molds on an injection molding machine.
Oh, okay. So, like, if you're done making one part Exactly. And you need to make a different one, how fast can you.
How quickly can you swap out those molds?
Okay, got it.
And your notes mention a case study where a company was able to reduce their changeover time.
Oh, wow.
From four hours down to just ten minutes.
What? That's amazing.
It's a huge difference.
Four hours to ten minutes.
Yeah. And it all comes down to a systematic approach to analyzing every step in that changeover process and finding ways to streamline or eliminate unnecessary actions.
So it's like a pit crew at a racing event.
Exactly.
You know, where every second counts.
Yeah. You've got to be super efficient.
And they've got it all choreographed.
Yeah, They've optimized every movement.
That's so cool.
And the impact on cost is significant. You know, reducing downtime means more production time.
Right.
Which means lower costs per unit.
That makes sense. And we can't talk about efficiency without talking about automation.
Oh, absolutely.
It seems like robots are everywhere in manufacturing these days.
For good reason.
Yeah.
You know, automating tasks like part removal, trimming, packaging can dramatically improve efficiency.
Okay.
Robots work tirelessly. They don't need brakes.
They don't complain.
They don't complain.
Yeah.
And they're incredibly precise.
Okay.
Plus, one of your articles points out that automation can actually improve safety.
Oh, how so?
You know, by taking over tasks that might be hazardous for human workers.
Oh, okay. Yeah, that makes sense.
So it's a win, win. You know, increased output, improved safety, and potentially lower labor costs.
Yeah. Right. So that's pretty cool. But I imagine even with automation, you still need those skilled humans.
Yeah. The human element is still essential. You know, skilled technicians are needed to program, operate and maintain those robots.
Right. And to check the quality, I imagine.
You got it. Quality control is absolutely paramount.
Yeah.
In injection molding, and that's still largely a human driven process.
Okay. So it's not just about making the parts. It's about making sure that's not making good parts, that they're good. Yeah, yeah.
You don't just want to crank out parts as quickly as possible. You need to make sure those parts meet the required specifications.
So what are some of the key things that need to be checked?
Well, dimensions and tolerances are critical. You know, making sure that the parts are the right size and shape.
Got it.
One of your articles talks about the use of precision measuring tools to ensure that parts meet those exact specifications.
Okay.
Because even tiny deviations can affect the part's functionality or its ability to fit properly.
So every little.
Every little micron matters.
A chromometer matters.
Wow. Yeah. It's all about precision and consistency.
Got it. And what about just, like, looking at it?
Visual inspections are important as well.
Okay.
Yeah. Trained inspectors look for any defects like surface blemishes, sink marks, warping.
Okay.
These visual cues can indicate underlying issues with the process or the materials.
So those humans have a really important role to play.
They do. Yeah. They're the ones with the eyes on the prize, so to speak.
All right, so quality control is very important.
Absolutely.
We don't want to have any defects.
Yeah. Catching those defects early prevents faulty parts from moving further down the production line, which saves time and materials and money.
Got it. Okay. So we've talked about making the process more efficient. Yeah, We've talked about quality control. What's the final piece of the puzzle when it comes to cost reduction?
Well, we've talked about a lot of different strategies, but it's all for nothing if we're not tracking our costs carefully.
Right. You can't Improve what? You don't measure.
Exactly. You need to know where your money going. Yeah. And identify areas for improvement. And that's where cost accounting comes in, right? Cost accounting, yeah. So cost accounting is really the key to making sure all these other efforts are actually paying off.
Okay. So it's not just about implementing these fancy strategies. We need to actually be tracking our costs to make sure that they're working.
You got to measure the impact.
Yeah.
Okay. So cost accounting, it helps you understand where your money's going.
Right.
And identify areas for improvement.
So it's like a financial microscope, I guess. Yeah.
You're zooming in.
Yeah. Looking at all the little.
On each stage of the process.
Details.
Yeah. And seeing where those cost savings are hiding.
Okay. And this doesn't have to be some super complicated system, does it?
No, not at all.
Okay.
Year notes mention a system where they track key metrics like material usage, energy consumption, labor hours, scrap rates.
Okay. So they're monitoring all those things.
Yeah. And by monitoring those numbers closely, they can see the direct impact of their cost saving measures.
So, for example, if material waste goes down right after they implement a recycling.
Program, that's a clear sign of success.
That's great. Okay.
And if energy consumption spikes unexpectedly.
Yeah.
It might indicate a problem with a machine.
Okay.
Or a need to adjust process parameters.
So it's like a dashboard warning light.
Exactly.
Yeah. Telling you something's wrong.
Pay attention. Something's going on here.
Okay. And if you're keeping track of all this over time.
Right.
You start to build up this historical record.
You can identify trends and patterns and make more informed decisions.
Okay. So data is king.
Data is king.
Got it. Okay. Well, we've been talking about cost reduction, but there's this other theme that keeps coming up, which is sustainability.
Absolutely.
So how do those two things fit together?
Well, sustainability is no longer just a buzzword. It's really an integral part of responsible manufacturing.
Yeah.
And what's really exciting is that it often goes hand in hand with cost reduction.
Oh, okay. Interesting.
Yeah. So one of your articles highlights a company that switched to using recycled plastic.
Oh, wow.
For some of their products.
And were they able to maintain the quality?
They did. In fact, they found that the recycled material performed just as well as the virgin plastic in their specific application.
Okay.
And because recycled plastic is often less expensive, they were able to reduce their material costs significantly.
So that's a win. Win.
It is. Yeah.
For the environment and for the.
For the bottom line.
Bottom line. That's great.
And it's not just about materials okay. Reducing energy consumption also plays a huge role. Your notes mentioned a company that implemented a system to capture and reuse the heat generated during the injection molding process.
So they're basically, like, recycling energy.
They're turning waste heat into a valuable resource.
This is pretty amazing.
Yeah. And that translates into lower energy bills and a smaller carbon footprint.
So it's like one sustainable choice leads to another.
It's a domino effect. Yeah. A ripple of positive impacts.
Well, this has been a really interesting conversation.
It has. Yeah.
We've covered a lot of ground, a.
Lot of different aspects of cost reduction.
So if we had to just, like, boil it all down into a few.
Key takeaways, what are the most important things?
For a listener, what would you say?
I think the most important thing is to start with a holistic mindset.
Holistic, okay.
Yeah. Look at every stage of the process, from design to production to disposal, and think about how they all connect.
Okay.
Optimize your mold design. Yeah. Choose your materials carefully. Fine tune your process parameters. Embrace automation where it makes sense.
Right.
But remember that skilled human expertise is still essential.
Got it.
And never underestimate the power of data.
Data.
Track your costs diligently and use that information to guide your decisions and build.
Good relationships with your suppliers.
Absolutely right.
And think about sustainability.
Those are key ingredients for success.
Well, you've given us a lot to think about.
My pleasure.
And I really appreciate you taking the time to. Happy to help share your expertise.
Yeah.
And for our listener out there, hopefully this gives you some.
Some food for thought.
Yeah. Some things to chew on as you're planning your next injection molding project.
The world of injection molding is constantly evolving. So stay curious, keep learning, keep learning, and never stop exploring new possibilities.
That's great advice.
Yeah.
I think that applies to everything, to life in general. All right, well, that wraps up this episode of the Deep Dive.
It does.
Thanks for joining us, and we'll see you next