Original Date: 07/23/1996
Revision Date: 01/18/2007

In May 1993, Nascote established a Flash Entrapment Task Force Team to reduce scrap caused by flash entrapment in the reinforced reaction injection molding process. Prior to that time the flash entrapment scrap rate was 5.48%. The team's objective was to reduce the scrap rate from 5.48% to 2% within six months.

The team applied root cause problem solving techniques to identify the best opportunities for improvements. This approach yielded a radical outcome that significantly improved the process to the desired level. The team flipped the tool upside down, contrary to accepted industry practice. By implementing this simple idea, the flash fell off the cavity rather than into it. The new method required substantial trial and error adjustments to perfect, and maintenance personnel reprogrammed the machine and drilled new holes on the tool to accommodate the crane and face plate modifications.

Flipping the tool resulted in many improvements, such as eliminating the oil dripping into the cavity, eliminating of flash entrapment, reducing spray usage, and reducing ergonomically-related problems. Drawbacks to flipping the tool were eliminated or reduced through further analysis by the team. Nascote's reversal of tool orientation for this process was unique in the industry. It resulted in substantial productivity improvements and cost reductions. Annual savings from this improvement totaled $162 thousand at current production levels.

For more information see the Point of Contact for this survey.