Thesis Defense - Oğuz Yasin (MSIE)

Oğuz Yasin – M.Sc. Industrial Engineering

Asst. Prof. Erinç Albey – Advisor

Date: 14.06.2021

Time: 13.00

Location: This meeting will be held ONLINE. Please send an e-mail to gizem.bakir@ozyegin.edu.tr in order to participate in this defense.

AVOIDING SHORT SHOT QUALITY FAILURE IN INJECTION MOLDING MACHINE

Thesis Committee:

Asst. Prof. Erinç Albey, Ozyegin University

Assoc. Prof. Örsan Okan Özener, Ozyegin University

Assoc. Prof. Mehmet Güray Güler, Yıldız Technical University

Abstract:

The Plastic injection molding machine (IMM) has been one of the most preferred manufacturing methods since its invention and continues its development in parallel with the advancing technology. The demand for faster, better quality, and cheaper parts with improved quality output is increasing day by day. Manufacturers are dealing with quality errors in production while trying to meet this demand. The most common of these quality errors are the short shot missing injection error. The special mold investment, changing of part design, and usage of distinct plastic raw materials are carried out to solve this error. The most practical temporary action taken to prevent this error in production is to increase the raw material's weight by optimizing the process parameters. Unfortunately, all of these solution methods increase the product cost.

This thesis aims to develop a system for preventing short shot quality failure without using a solution to massive increase the part's cost. Firstly, the finite element analysis (FEA) for the short shot quality defect in injection machinery molding (IMM) is performed via Autodesk Moldflow Analysis. The mold flow FEA model is verified in serial production. Then, IMM is integrated into the manufacturing execution system (MES) and a quality control system with cameras installed at the end of the production line. The relationship between short shot quality defect and IMM critical process parameters extracted with data analytic. The model is generated and commissioned in the production line. The integration of each production line into MES and installing a camera measurement system can adversely affect industrial deployment sustainability. Therefore, a different approach is developed with in-mold pressure/temperature sensors.

The production parameters affecting the short shot quality failure are determined via data analytics. The goal is to produce the system in the ideal range in each cycle by giving feedback to the IMM according to the in-mold sensors' data during production. The main aim of this thesis is to avoid short-shot quality failure in plastic part production. The short-shot quality defect has not been eliminated in this study. However, it has decreased from 3.7% error rates to 0.82%. This dramatic reduction results in an overall 80% improvement in short shot quality failure without increasing product cost.

Bio: 

Oğuz Yasin received a B.S. degree in Mechanical Engineering from Kocaeli University, Turkey, in 2012, and his master’s degree, which he started in 2018, continues in Industrial Engineering at Özyeğin University under the supervision of Asst. Prof. Dr. Erinç Albey. He has been working for more than eight years and his prior role was Production/Maintenance/R&D senior specialist at Arçelik Technology Company.