Quality Control and Process Optimization of Injection Molding Using a Data-Oriented Approach in an Industrial Setting

Abstract

This article proposes a data-driven scheme for quality control and process optimization of injection molding in industrial plants. The suggested approach enables the operators to find optimal process parameters that enable producing high quality parts. Additionally, it allows early detection of defects through monitoring variations of process parameters. The implementation of the suggested scheme is investigated in a factory, where an on-site test is conducted, and outcomes are validated using a process capability analysis. The adopted approach and various levels of data processing are described, followed by a detailed explanation of the implementation steps and an on-site test to assess its effectiveness. The obtained results indicate an increase in production quality, reduced surface-level defects by 52.47%, a 92.5% decrease in the variation of pressure, and less than 2 ms variation in injection time. Furthermore, the process capability analysis resulted in a stabilized process with lower weight variations as reflected with the related (cpk) index, proving the approach to be capable of producing conforming products.