DESIGN OF EXPERIMENTS SOFTWARE INJECTION MOLDING INTRODUCTION TO NAUTILUS 8 MOLD QUALIFICATION AND DESIGN OF EXPERIMENTS SOFTWARE FOR INJECTION MOLDING SUHAS KULKARNI FIMMTECH 1-760-525-9053

SUHAS KULKARNI FIMMTECH 1-760-525-9053 Nautilus is a program that helps in the evaluation, analysis, development and documentation of the injection molding process. The software also has a complete design of experiments module that is customized for injection molding Once a process has been established on one machine, the software will calculate the processes for all the machines in the shop. The process can now be transferred and ‘starting from scratch’ will not be necessary on the other machines SUHAS KULKARNI FIMMTECH 1-760-525-9053

SUHAS KULKARNI FIMMTECH 1-760-525-9053 Benefits Of Using The Techniques: Established process is robust Process will require ‘no or little attention’ Will determine the fastest cycle time possible Less scrap at startup Zero scrap during production Improved part quality and process capability Above factors increase the bottom line profits! SUHAS KULKARNI FIMMTECH 1-760-525-9053

SUHAS KULKARNI FIMMTECH 1-760-525-9053 THE SOFTWARE SUHAS KULKARNI FIMMTECH 1-760-525-9053

SUHAS KULKARNI FIMMTECH 1-760-525-9053 Following are some of the features of the software: Material, Mold and Machine databases Mold – Machine Compatibility report Scientific Molding Worksheets (6-step study) Viscosity study Pressure drop study cavity balance study Process window study Gate seal study cooling time SUHAS KULKARNI FIMMTECH 1-760-525-9053

SUHAS KULKARNI FIMMTECH 1-760-525-9053 Design Of Experiments Module Tornado Charts Process Sensitivity Charts Cosmetic Process Window Dynamic Process Window Visual Prediction Equation Mold trial and qualification progress report water line diagrams and mold temperature maps Mold setup and operation documentation SUHAS KULKARNI FIMMTECH 1-760-525-9053

SUHAS KULKARNI FIMMTECH 1-760-525-9053 Quality module Full dimensional analysis Statistical analysis Post molding shrinkage report Documentation of quality inspection plan Calculation worksheets commonly used in molding User privileges Choice of units Network/concurrent versions SUHAS KULKARNI FIMMTECH 1-760-525-9053

SUHAS KULKARNI FIMMTECH 1-760-525-9053 SUMMARY OF ADDITIONS TO VERSION 8: Process – Machine compatibility Add a plastic process sheet for a given mold Generate the plastic process sheet for any given machine Determine the machines in the shop that are compatible and capable of running the mold based on plastic variables Units management – Select between metric, english or a combination Auto convert on demand Once units for a given machine are saved all process sheets are generated in the machine units SUHAS KULKARNI FIMMTECH 1-760-525-9053

SUHAS KULKARNI FIMMTECH 1-760-525-9053 SUMMARY OF ADDITIONS TO VERSION 8: User Access Levels Determine who can and cannot change databases and documents Custom read/write access Ability to create family molds and run them through 6-step study, for example: determine cavity imbalances between family parts Doe, select the processes for family molds Optimize for all family parts Miscellaneous: All studies/documents for a given mold under one tab Additional fields added to all databases SUHAS KULKARNI FIMMTECH 1-760-525-9053

SUHAS KULKARNI FIMMTECH 1-760-525-9053 MAIN SCREEN: SUHAS KULKARNI FIMMTECH 1-760-525-9053

SUHAS KULKARNI FIMMTECH 1-760-525-9053 DATABASES: MATERIAL – MOLD – MACHINE SUHAS KULKARNI FIMMTECH 1-760-525-9053

SUHAS KULKARNI FIMMTECH 1-760-525-9053 Mold Machine Compatibility Report: Criteria based on Required tonnage % Shot size used Residence time of the material in the barrel Physical size of the mold and the machine specs SUHAS KULKARNI FIMMTECH 1-760-525-9053

SUHAS KULKARNI FIMMTECH 1-760-525-9053 Process – Machine Compatibility Add a plastic process sheet for a given mold SUHAS KULKARNI FIMMTECH 1-760-525-9053

SUHAS KULKARNI FIMMTECH 1-760-525-9053 Process – Machine Compatibility Generate the plastic process sheet for any given machine in the database Determine if the machines are capable of running the mold based on plastic variables Established Process Calculated Process Sheets For Other Machines NOT ACCEPTABLE ACCEPTABLE SUHAS KULKARNI FIMMTECH 1-760-525-9053

SUHAS KULKARNI FIMMTECH 1-760-525-9053 Process – Machine Compatibility Once the target machine is selected, select the process sheet from the drop down list and click on ‘generate process sheet’ to print the process sheet for the machine SUHAS KULKARNI FIMMTECH 1-760-525-9053

Mold Qualification Part 1: 6-step Study (Aka: Scientific Molding) SUHAS KULKARNI FIMMTECH 1-760-525-9053

SUHAS KULKARNI FIMMTECH 1-760-525-9053 WORKSHEET NO. 1: IN MOLD RHEOLOGY SUHAS KULKARNI FIMMTECH 1-760-525-9053

SUHAS KULKARNI FIMMTECH 1-760-525-9053 WORKSHEET NO. 2: CAVITY BALANCE STUDY SUHAS KULKARNI FIMMTECH 1-760-525-9053

SUHAS KULKARNI FIMMTECH 1-760-525-9053 WORKSHEET NO. 3: PRESSURE DROP STUDY SUHAS KULKARNI FIMMTECH 1-760-525-9053

SUHAS KULKARNI FIMMTECH 1-760-525-9053 WORKSHEET NO. 4: COSMETIC PROCESS WINDOW SUHAS KULKARNI FIMMTECH 1-760-525-9053

SUHAS KULKARNI FIMMTECH 1-760-525-9053 WORKSHEET NO. 5: GATE SEAL STUDY – COLD RUNNER SUHAS KULKARNI FIMMTECH 1-760-525-9053

SUHAS KULKARNI FIMMTECH 1-760-525-9053 WORKSHEET NO. 5: GATE SEAL STUDY – HOT RUNNER SUHAS KULKARNI FIMMTECH 1-760-525-9053

SUHAS KULKARNI FIMMTECH 1-760-525-9053 WORKSHEET NO. 6: COOLING STUDY SUHAS KULKARNI FIMMTECH 1-760-525-9053

WORKSHEET FOR HOT RUNNER AND VALVE GATED MOLDS SUHAS KULKARNI FIMMTECH 1-760-525-9053

MOLD QUALIFICATION PART 2: DESIGN OF EXPERIMENTS SUHAS KULKARNI FIMMTECH 1-760-525-9053

SUHAS KULKARNI FIMMTECH 1-760-525-9053 Key features: No prior math or statistics experience required With 4 easy steps you will be able to design a doe and run the experiments. The data will visually show you what you can and cannot mold as far as the dimensions of the part are concerned. No guesswork: data driven decisions for all changes in mold steel and/or nominal - specifications Adjust the steel with confidence and leave the process alone! SUHAS KULKARNI FIMMTECH 1-760-525-9053

INPUTS WORKSHEETS FOR DOE: STEP 1: SELECT THE FACTORS FROM A DROPDOWN LIST SUHAS KULKARNI FIMMTECH 1-760-525-9053

SUHAS KULKARNI FIMMTECH 1-760-525-9053 STEP 2: ENTER THE UNITS, HIGH AND LOWS FOR THE STUDIES THE HIGHS AND LOWS ARE DETERMENIED FROM THE COSMETIC PROCESS WINDOW. SUHAS KULKARNI FIMMTECH 1-760-525-9053

SUHAS KULKARNI FIMMTECH 1-760-525-9053 STEP 3: ENTER THE NOMINALS AND TOLERANCES SUHAS KULKARNI FIMMTECH 1-760-525-9053

SUHAS KULKARNI FIMMTECH 1-760-525-9053 STEP 3: SOFTWARE GENERATES THE EXPERIMENTAL MATRIX MOLD THE PARTS, ENTER DATA AND CLICK ON THE ANALYSIS BUTTON TO VIEW THE RESULTS SUHAS KULKARNI FIMMTECH 1-760-525-9053

SUHAS KULKARNI FIMMTECH 1-760-525-9053 TORNADO CHARTS GIVES YOU INFO ON THE FACTOR THAT MOST IMPACTS THE PART QUALITY (POSITIVE FACTORS ABOVE THE LINE, AND NEGATIVE BELOW THE LINE) SUHAS KULKARNI FIMMTECH 1-760-525-9053

SUHAS KULKARNI FIMMTECH 1-760-525-9053 PROCESS SENSITIVITY GRAPH GIVES YOU A QUICK SNAP SHOT OF HOW THE DIMENSION WAS AFFECTED BY THE DOE PROCESS RUN SUHAS KULKARNI FIMMTECH 1-760-525-9053

SUHAS KULKARNI FIMMTECH 1-760-525-9053 DETERMINING THE OPTIMUM PROCESS BASED ON SELECTED CAVITIES AND DIMENSIONS SUHAS KULKARNI FIMMTECH 1-760-525-9053

SUHAS KULKARNI FIMMTECH 1-760-525-9053 DIMENSIONAL PROCESS WINDOW GREEN CONTOURS – PARTS IN DIMENSION RED – PARTS OUT OS SPEC YOU CAN DRAW A BOX AS SHOWN TO DETERMINE ALARM AND TOLERANCE SETTINGS DIMENSIONAL PROCESS WINDOW SUHAS KULKARNI FIMMTECH 1-760-525-9053

SUHAS KULKARNI FIMMTECH 1-760-525-9053 DIMENSIONAL PROCESS WINDOW MOLD PARTS BETWEEN THE PROCESS WINDOWS TO MAINTAIN THE PARTS WITHIN THE DIMENSIONS. DIMENSIONAL PROCESS WINDOW SUHAS KULKARNI FIMMTECH 1-760-525-9053

SUHAS KULKARNI FIMMTECH 1-760-525-9053 DIMENSIONAL PROCESS WINDOW WITH A DIMENSIONAL PROCESS WINDOW AS SHOWN IT WILL BE IMPOSSIBLE TO MOLD PARTS CONSISTENTLY TO THE REQUIRED DIMENSIONS. IT WILL BE IMPOSSIBLE TO OBTAIN GOOD CpKs TIME TO MAKE A DATA DRIVEN DECISION! SUHAS KULKARNI FIMMTECH 1-760-525-9053

SUHAS KULKARNI FIMMTECH 1-760-525-9053 VISUAL PREDICTION EQUATION THE DIMENSION CAN GO OUT OF SPEC USL LSL Cavity No → EXTENT TO WHICH THE DIMENSION CAN BE INFLUENCED BETWEEN THE EXTREMES OF THE DOE PARAMETERS USL LSL Cavity No → SUHAS KULKARNI FIMMTECH 1-760-525-9053

SUHAS KULKARNI FIMMTECH 1-760-525-9053 VISUAL PREDICTION EQUATION THE DIMENSION CAN GO OUT OF SPEC USL LSL Cavity No → STABLE DIMENSION – WILL ALWAYS BE IN SPEC USL LSL LSL Cavity No → SUHAS KULKARNI FIMMTECH 1-760-525-9053

SUHAS KULKARNI FIMMTECH 1-760-525-9053 VISUAL PREDICTION EQUATION PROCESS GOLD SPOT - BEST PROCESS TO BRING ALL DIMENSIONS CLOSEST TO NOMINAL USL LSL Cavity No → STABLE DIMENSION – WILL ALWAYS BE IN SPEC USL LSL Cavity No → SUHAS KULKARNI FIMMTECH 1-760-525-9053

SUHAS KULKARNI FIMMTECH 1-760-525-9053 VISUAL PREDICTION EQUATION SIMULATED PROCESS: CHANGE THE PROCESS AND SEE WHAT IT DOES TO THE PART DIMENSIONS. THE BLACK X WILL MOVE WITH PROCESS CHANGES (SEE NEXT SLIDE) USL LSL Cavity No → USL Cavity No → SUHAS KULKARNI FIMMTECH 1-760-525-9053

SUHAS KULKARNI FIMMTECH 1-760-525-9053 VISUAL PREDICTION EQUATION SIMULATED PROCESS: CHANGE THE PROCESS AND SEE WHAT IT DOES TO THE PART DIMENSIONS. THE BLACK X WILL MOVE WITH PROCESS CHANGES SUHAS KULKARNI FIMMTECH 1-760-525-9053

SUHAS KULKARNI FIMMTECH 1-760-525-9053 NUMERICAL PREDICTION EQUATION USE THE ARROWS TO CHANGE THE PROCESS AND SEE THE EFFECT ON THE DIMENSIONS. DIMENSIONS ARE DISPLAYED NUMERICALLY SUHAS KULKARNI FIMMTECH 1-760-525-9053

Target Seeker The user can select any one cavity and any one dimension and input the required target and the software will predict the process to achieve the target. In some cases, the target is not achievable because of the high and low limits. The difference is displayed. The user can select the Nominal, LSL, USL or enter their own value.

Max Dimensional Acceptance: The user can select any of the dimensions and the cavities and the software will predict the process where those dimensions will be as close to bringing within the specifications. Please see the slide towards the end of the presentation to better understand the difference between the Gold Spot and Max Dimensional Acceptance.

New Tab: Lowest Cooling Time Process: Keeping the lowest time at the lowest possible value – what is the process where all the dimensions are as close as possible to the nominal? Select the cavities and the dimensions and click on ‘Seek Process’ and the software will predict the process

Difference between ‘Gold Spot’ and ‘Max Part Acceptance’ Original Process Gold Spot Max part Acceptance Dimensions are as close as possible to nominal A process is predicted to bring the parts within specifications X Y Reqd change Reqd change X Y X Y Dimension A Dimension B Please note at these predictions the parts may not be in spec. The software runs an analysis to predict the process each process.

SUHAS KULKARNI FIMMTECH 1-760-525-9053 Achieving Dimensions: Making Steel And/Or Nominal – Tolerance Changes Good Cp but a bad Cpk??? Your Choices Are Modify The Steel Dimension And/Or Modify The Nominal – Spec Limits ROBUST PROCESS MODIFY MOLD AND/OR NOMINAL-SPEC LIMITS BY THIS NUMBER TO HIT THE MOMINAL VALUE SUHAS KULKARNI FIMMTECH 1-760-525-9053

SUHAS KULKARNI FIMMTECH 1-760-525-9053 Capability not a requirement? Want to be only in spec?? ROBUST PROCESS MODIFY MOLD AND/OR NOMINAL-SPEC LIMITS BY THIS NUMBER TO HIT BE INSIDE THE USL OR LSL SUHAS KULKARNI FIMMTECH 1-760-525-9053

SUHAS KULKARNI FIMMTECH 1-760-525-9053 CONFIDENCE RATINGS Use the arrows to change the process and see the effect on the dimensions. Dimensions are displayed numerically SUHAS KULKARNI FIMMTECH 1-760-525-9053

PRINTING: SELECTION SCREEN SUHAS KULKARNI FIMMTECH 1-760-525-9053

PRINTING: EXPORTED REPORT AND ‘SAVE AS’ OPTIONS SUHAS KULKARNI FIMMTECH 1-760-525-9053

MOLD SPECIFIC TROUBLE SHOOTING GUIDE SUHAS KULKARNI FIMMTECH 1-760-525-9053

SUHAS KULKARNI FIMMTECH 1-760-525-9053 QUALITY MODULE: FULL DIMENSIONAL ANALYSIS: SUHAS KULKARNI FIMMTECH 1-760-525-9053

SUHAS KULKARNI FIMMTECH 1-760-525-9053 QUALITY MODULE: STATISTICAL ANALYSIS : SUHAS KULKARNI FIMMTECH 1-760-525-9053

SUHAS KULKARNI FIMMTECH 1-760-525-9053 MACHINE QUALIFICATION: INJECTION SPEED LINEARITY : SUHAS KULKARNI FIMMTECH 1-760-525-9053

SUHAS KULKARNI FIMMTECH 1-760-525-9053 MACHINE QUALIFICATION: SHOT TO SHOT REPEATABILITY TEST : SUHAS KULKARNI FIMMTECH 1-760-525-9053

SUHAS KULKARNI FIMMTECH 1-760-525-9053 MACHINE QUALIFICATION: LOAD SENSITIVITY TEST : SUHAS KULKARNI FIMMTECH 1-760-525-9053

SUHAS KULKARNI FIMMTECH 1-760-525-9053 FREQUENTLY USED MOLDING CALCULATIONS: SUHAS KULKARNI FIMMTECH 1-760-525-9053

SUHAS KULKARNI FIMMTECH 1-760-525-9053 WATER FLOW CALCULATION: SUHAS KULKARNI FIMMTECH 1-760-525-9053

SUHAS KULKARNI FIMMTECH 1-760-525-9053 PROCESS TRANSFER BETWEEN MACHINES WORKSHEET: SUHAS KULKARNI FIMMTECH 1-760-525-9053

SUHAS KULKARNI FIMMTECH 1-760-525-9053 SHOT SIZE ESTIMATION WORKSHEET: SUHAS KULKARNI FIMMTECH 1-760-525-9053

SUHAS KULKARNI FIMMTECH 1-760-525-9053 HOPPER SIZE CALCULATION WORKSHEET: SUHAS KULKARNI FIMMTECH 1-760-525-9053

SUHAS KULKARNI FIMMTECH 1-760-525-9053 REGRIND CALCULATIONS (CLOSED LOOP SYSTEMS) SUHAS KULKARNI FIMMTECH 1-760-525-9053

MISCELLANEOUS FEATURES SUHAS KULKARNI FIMMTECH 1-760-525-9053

SUHAS KULKARNI FIMMTECH 1-760-525-9053 NEW IN VER 8 UNITS MANAGEMENT UNITS MANAGEMENT – SELECT BETWEEN METRIC, ENGLISH OR A COMBINATION AUTO CONVERT ON DEMAND SUHAS KULKARNI FIMMTECH 1-760-525-9053

SUHAS KULKARNI FIMMTECH 1-760-525-9053 NEW IN VER 8 USER ACCESS LEVELS USER ACCESS LEVELS DETERMINE WHO CAN AND CANNOT CHANGE DATABASES AND DOCUMENTS CUSTOM READ/WRITE ACCESS SUHAS KULKARNI FIMMTECH 1-760-525-9053

SUHAS KULKARNI FIMMTECH 1-760-525-9053 NEW IN VER 8 FAMILY MOLDS ABILITY TO CREATE FAMILY MOLDS AND RUN THEM THROUGH 6-STEP STUDY, FOR EXAMPLE: DETERMINE CAVITY IMBALANCES BETWEEN FAMILY PARTS DOE, SELECT THE PROCESSES FOR FAMILY MOLDS OPTIMIZE FOR ALL FAMILY PARTS SUHAS KULKARNI FIMMTECH 1-760-525-9053

SUHAS KULKARNI FIMMTECH 1-760-525-9053 FAMILY MOLDS NEW IN VER 8 ABILITY TO CREATE FAMILY MOLDS IN THE DATABASE SUHAS KULKARNI FIMMTECH 1-760-525-9053

SUHAS KULKARNI FIMMTECH 1-760-525-9053 FAMILY MOLDS NEW IN VER 8 ABILITY TO QULAIFY FAMILY MOLDS IN 6-STEP AND DOE MODULE SUHAS KULKARNI FIMMTECH 1-760-525-9053

SUHAS KULKARNI FIMMTECH 1-760-525-9053 CONTACT INFO: SUHAS KULKARNI suhas@fimmtech.com 1-760-525-9053 WWW.FIMMTECH.COM WWW.INJECTIONMOLDINGONLINE.COM SUHAS KULKARNI FIMMTECH 1-760-525-9053