1. Acme Yo-yo Company Omar Hernandez, Alex Slocum, Jr. – Yo-Yo Base Kimberlee Collins & Rosa Rodriguez - Wiley Cover Dayan Paez – Clear Cover and Snap-fit retaining ring

2. Assembly

3. Base Optimization Optimization Order –Shot size –Cool Time –Hold Size –Sprue- break Results: –SS: 3.25 in –HT: 60 sec –CT: 90 sec Cycle time –100 sec

4. Base Process Details Process capacity –C p =.298 Higher since actual tolerances spec range is greater than 0.005 in. Cycle Time –100 seconds, steady state Production –125 bases producted Some got stuck on mold Several short shots.

5. Conclusion Rate: very difficult to increase. Problems: –Cooling Time. –1 st generation mold was too big. Flexibility –Geometry: limited Cooling time –Color: whatever was in the hopper. Cost: relatively high due to low rate/large part size. Ways quality can be increased: –Draft angles –MoldFlow™ –Address uneven cooling

6. Wiley Centerpiece Injection Molding Piece by Rosa Rodriguez and Kimberlee Collins

7. Inspiration Can you find him???

8. Drawing

9. Optimization Order –Shot size –Hold time –Cool time Results –SS: 0.62 in –HT: 5 sec –CT: 9 sec “Cycle time” –15 sec on automatic

10. Production Process capacity –C p = 8.33 Cycle Time –8 seconds, steady state Number produced –133 parts, of 3 distinct colors

11. Conclusion Rate: hard to increase without another machine (2 at a time) Flexibility –Geometry: limited Cool time –Color: great Cost: low due to small volume Quality: using a ball end mill, the core finish could be improved; avoid clear plastic

12. Retaining Ring Injection Molding by Dayán Páez

13. Drawing

14. Optimization Order –Shot size –Hold time –Cool time Results –SS: 0.70 in –HT: 3 sec –CT: 3 sec “Cycle time” –8 sec on automatic

15. Process Details Process capacity –C p =.307 Higher since actual tolerances spec range is greater than 0.005 in. Cycle Time –8 seconds, steady state Number produced –200 parts, of 5 distinct colors

16. Conclusion Rate: hard to increase without a bigger machine (2 at a time) Flexibility –Geometry: limited Cool time –Color: great Cost: low due to small volume Quality: can be increased through use of proper equipment (e.g. CNC Lathe)

17. Clear Cover Thermoform by Dayán Páez

18. Drawing

19. Optimization Criteria: visual quality Order –Form time –Varied between temperature and heat time. Results –Heat time: 30 sec –Form time: 15 sec –Temperature: 575 °F “Cycle time” –~60 sec in steady state

20. Process Details Process capacity –C p = 4.71 (!) High due to flexibility in spec range. Cycle Time –60 seconds, steady state Number produced –100 parts at 1% error

21. Conclusion Rate: can best be increased by doing more at a time. Flexibility –Plastic thickness: limited to ≤ 0.030 in Cost: low due to small error rate Quality: heavily dependent on operator

22. Overall Integration of parts –Tight snap fit Assembly: 50 yoyos Functionality –Stable