FORD W-IMMS-2015 CONTROL OF PLASTIC INJECTION MOLDING PROCESSES (3RD Edition).pdf

1、 Printed Copies are Uncontrolled 1 of 52 Global Manufacturing Standards W-IMMS Control of Plastic Injection Molding Processes Third Edition Issued: 1-December-2015 FORD GLOBAL MANUFACTURING STANDARD CONTROL OF PLASTIC INJECTION MOLDING PROCESSES W-IMMS Third Edition Printed Copies are Uncontrolled 2

2、 of 52 Global Manufacturing Standards W-IMMS Control of Plastic Injection Molding Processes Third Edition Issued: 1-December-2015 EXECUTIVE SPONSORS David Malecki Senior Manager, STA Global Technical Services Kathy Minnich Manager, Core Materials Engineering AUTHORS Larry Xu Technical Expert, Plasti

3、c Injection Molding Global Lead, STA Global Technical Services Arturo Ayala Technical Specialist, Plastic Injection Molding, Mexico STA Fabricio Orlandi Technical Specialist, Plastic Injection Molding, South America STA Ferenc Toth Technical Specialist, Plastic Injection Molding, Europe STA Prabhu K

4、SNP Technical Specialist, Plastic Injection Molding, Asia Pacific STA Joshua Boker PD Engineer, Design Quality Li Qi Mold Flow Analysis Lead, PD Electrical Analysis Chad Korte Technical Expert, Energy System Engineering Mike Masserant TS/Supervisor, Core Body Interior Engineering Chris Mracna Superv

5、isor, Chassis Materials Engineering Robert Parsons Senior Tooling Engineer, Global Tooling Alan Reaume Technical Expert, Core Materials Engineering Sami Siddiqui Supervisor, CAE Manufacturing, Global PTI Analytical Product Engineering CONTRIBUTORS Alejandro Aquilar STA Electrical Manager, Americas F

6、ernando Cruz Site STA, Americas Barb Doelle Site STA, Americas Paulo Knecht Site STA, Americas Marcelo Koll Site STA, Americas Gregory Lobo Site STA, Americas Nisha Patel STA Program Manager, Americas Abdul Rao Site STA, Americas Rehan Syed STA Interior Site Manager, Americas Zsolt Bereczki Site STA

7、, Europe Rifat Arapoglu Site STA, Europe Hai Li STA Site Manager, Asia Pacific Paul Lindner Site STA, Asia Pacific Rudy Shen Site STA, Asia Pacific Steve Bazinski Supervisor, Design Quality Matthew Gramlich Materials Engineer, Core Materials Engineering Jeffrey Kloberdanz CAE Engineer, PD Electrical

8、 Analysis George Kowalski Materials Engineer, Core Materials Engineering Pilar Melero PD Engineer, Americas Linda Schmalz Supervisor, Core Materials Engineering Laura Soreide Resin Strategy Supervisor, Core Materials Engineering Mustafa Usuf D and R, NAC Fuel System Printed Copies are Uncontrolled 3

9、 of 52 Global Manufacturing Standards W-IMMS Control of Plastic Injection Molding Processes Third Edition Issued: 1-December-2015 REVISION NOTES Date Version Major Changes January 10, 2013 2nd edition In Sections 1 through 5, revised and added sentences when needed. e.g. use of “shall” instead of “s

10、hould” to emphasize a mandatory requirement, addition of the purpose of “Critical Response List” January 10, 2013 2nd edition In Section 6, added two special applications: 6.9 Mucell Process and 6.10 Natural Fiber Reinforced Polypropylene January 30, 2013 2nd edition In Appendix C, added fill time a

11、s process monitoring item June 10, 2015 3rd edition In Section 3, added 3.2 Machine Robustness June 25, 2015 3rd edition In Appendix A, added A1.2 Machine Robustness November 5, 2015 3rd edition In Section 2, added 2.2 Appearance Approval Standard November 5, 2015 3rd edition In Section 4, added 4.5

12、.2 Monitoring of Part Appearance November 5, 2015 3rd edition Added Appendix D, Evaluation Tools for Comparing to Minimum Appearance Standard November 11, 2015 3rd edition Added Appendix E, W-IMMS Compliance Checklist Printed Copies are Uncontrolled 4 of 52 Global Manufacturing Standards W-IMMS Cont

13、rol of Plastic Injection Molding Processes Third Edition Issued: 1-December-2015 TABLE OF CONTENTS 1. SCOPE 1.1 GENERAL DESCRIPTION . 1.2 APPLICATIONS AND LIMITATIONS 2. GENERAL REQUIREMENTS 2.1 ENGINEERING AND PROCESS SPECIFICATIONS 2.2 APPEARANCE APPROVAL STANDARD . 2.3 CONTROL PLAN 3. PART, MOLD

14、AND PROCESS ROBUSTNESS EXPECTATIONS . 3.1 PART AND MOLD ROBUSTNESS . 3.2 MACHINE ROBUSTNESS . 3.3 PROCESS ROBUSTNESS 4. PROCESS CONTROL AND MONITORING EXPECTATIONS 4.1 PROCESS SPECIFICATION . 4.2 DRYING . 4.3 PROCESS STARTUP 4.4 FIRST AND LAST PIECE INSPECTION 4.5 IN-PROCESS MONITORING . 4.6 PROCESS

15、 CHANGES . 4.7 USE OF MATERIAL IDENTIFICATION LABELS 5. MOLD AND MACHINE PREVENTIVE MAINTENANCE EXPECTATIONS . 5.1 MOLD SPECIFIC PREVENTIVE MAINTENANCE . 5.2 DETECTION OF EMERGING MOLD MAINTENANCE NEEDS . 5.3 MACHINE STATUS MONITORING PREVENTIVE MAINTENANCE . 6. ADDITIONAL GUIDELINES FOR SPECIAL APP

16、LICATIONS 6.1 MOLDING FOR CHROME PLATING 6.2 SENSOR OVERMOLDING 6.3 HIGH FILLER CONTENT MATERIALS 6.4 THERMOSET PLASTICS . 6.5 COLOR AT PRESS 6 6 7 7 7 8 8 8 8 10 10 12 12 12 13 14 15 16 17 17 17 17 18 18 18 20 22 23 24 Printed Copies are Uncontrolled 5 of 52 Global Manufacturing Standards W-IMMS Co

17、ntrol of Plastic Injection Molding Processes Third Edition Issued: 1-December-2015 6.6 LONG GLASS FIBER REINFORCED POLYPROPYLENE . 6.7 STORING AND SHIPPING MOLDED NYLON PARTS 6.8 LIVING HINGE. 6.9 MUCELL PROCESS . 6.10 NATURAL FIBER REINFORCED POLYPROPYLENE . 7. CRITICAL RESPONSE LIST 24 25 25 26 28

18、 30 APPENDICES A: PART, MOLD, AND PROCESS ROBUSTNESS ASSESSMENT B: A METHOD FOR ESTABLISHING STARTUP WINDOW C: RECOMMENDED METHODS AND FREQUENCIES FOR IN-PROCESS MONITORING D: EVALUATION TOOLS FOR COMPARING TO MINIMUM APPEARANCE STANDARD . E: W-IMMS COMPLIANCE CHECKLIST 31 31 48 50 51 52 Printed Cop

19、ies are Uncontrolled 6 of 52 Global Manufacturing Standards W-IMMS Control of Plastic Injection Molding Processes Third Edition Issued: 1-December-2015 1. SCOPE 1.1 GENERAL DESCRIPTION This standard defines the requirements for the control of plastic injection molding processes. These requirements r

20、eflect the following manufacturing concepts: Robust part and mold designs lay the foundation of a robust injection molding process. Process consistency, shot to shot and run to run, is the first step towards producing quality injection molded parts. Startup verification plays an important role in pr

21、eventing injection molding process mean shift over time. In-process machine and process status monitoring is necessary to provide an early warning for potential quality deviations. Effective machine and mold preventive maintenance contributes to process consistency in long term production. Proper ve

22、rifications are necessary when changes in process, part, mold, or machine take place. The manufacturing standard and its appendices include methods and criteria for assessing the robustness of part design, mold design and fabrication, and molding process, as well as methods and frequencies of in-pro

23、cess monitoring. Below is a list of the methods: Evaluating the robustness of the design of an injection molded plastic part Evaluating the robustness of a production tool Evaluating robustness of a production process Establishing injection molding process window Injection molding process monitoring

24、 Injection molding machine status monitoring Detecting emerging mold maintenance needs Establishing instructions for first and last piece inspection Appendix A: “Part, Mold, Machine, and Process Robustness Assessment” lists the recommended evaluation methods and robustness criteria. If a production

25、process fails to meet robustness criteria, the molder should increase process monitoring frequency and sample size to ensure product quality. When a plastic part quality issue arises, the Critical Response List is recommended to Ford suppliers as a reference for proper actions during problem solving

26、. Appendix E: “W-IMMS Compliance Checklist” provides a tool for the molder to assess whether its injection molding system meets the requirements in W-IMMS. The molder should always refer to the main text of this standard for details and clarification of each requirement. To facilitate the assessment

27、, a workbook of the Printed Copies are Uncontrolled 7 of 52 Global Manufacturing Standards W-IMMS Control of Plastic Injection Molding Processes Third Edition Issued: 1-December-2015 checklist in Excel format (also known as Ford Specific CQI-23 Assessment) has been developed and the document is avai

28、lable to Ford suppliers. 1.2 APPLICATIONS AND LIMITATIONS This standard applies to all plastic injection molded production and service parts manufactured by tier 1 and sub-tier suppliers to Ford Motor Company. Exceptions to the standard shall be reviewed and concurred by Ford Supplier Technical Assi

29、stance (STA). The intent of this standard is to deploy specific plastic molding best practices and lessons learned that are proven effective in the development and control of injection molding processes, as well as in the prevention of recurrence of quality issues. For plastic molding general qualit

30、y practices, molding suppliers to Ford Motor Company are required to conduct self-assessment by using AIAG CQI-23: Special Process: Molding System Assessment. This standard uses key items in injection molded part design, mold design, and mold construction as design for manufacturing indicators, defi

31、nes assessment methods, and sets part and mold robustness criteria based on benchmark data. However this standard should not be interpreted as a part design standard or a tooling standard for injection molded parts. Whenever a conflict between this standard and an applicable engineering specificatio

32、n or between this standard and an applicable tooling specification arises, final decision shall be made by a team consisting of Ford Engineering, Ford STA, and the supplier or the suppliers. In this standard, the word “shall” indicates a requirement. Suppliers need to take immediate actions to addre

33、ss areas that fail to meet the requirements. The word “should” indicates a recommendation. Where the term “such as” is used, suggestions given are for guidance only. 2. GENERAL REQUIREMENTS 2.1 ENGINEERING AND PROCESS SPECIFICATIONS The molder shall have an engineering drawing or specification that

34、lists engineering requirements of the part. Engineering requirements include the material specification (if applicable, material type and grade), dimensions, and performance requirements. The molder shall have a mold design that includes specifications for mold components, locking mechanism, ejectio

35、n mechanism, and cooling lines. The molder shall establish a process specification that defines operating ranges of machine variables such as barrel temperature, transfer position, and screw velocity etc. Printed Copies are Uncontrolled 8 of 52 Global Manufacturing Standards W-IMMS Control of Plasti

36、c Injection Molding Processes Third Edition Issued: 1-December-2015 2.2 APPEARANCE APPROVAL STANDARD The molder shall comply with Ford G-DCAP (Global Decorative Component Approval Process). The document is available to Ford suppliers via Ford Supplier Portal. Part appearance is a product characteris

37、tic designated in the DFMEA with the “YS” symbol (potential significant characteristic). All production parts shall meet appearance requirements for color, texture, gloss, parting lines and other surface defects. The minimum appearance standard is defined by the stickered part signed off by Ford Des

38、ign Quality along with a corresponding AAR (Appearance Approval Report). For color, production parts shall be in the correct color space trending direction as defined by Ford Design Quality. The molder shall refer to Appendix D for appearance evaluation method. The molder shall retain the stickered

39、part for the life of a vehicle program. All stickered parts shall be stored in a dedicated and clearly defined location. 2.3 CONTROL PLAN A written Control Plan is required for the processing of all injection molded parts covered by this standard. The Control Plan shall be linked to Process Failure

40、Mode and Effect Analysis and shall contain proper reaction plans to handle process deviations. The Control Plan should include first and last piece inspection. Parameters that reflect feedbacks from the molding process should be used for process monitoring purpose. 3. PART, MOLD AND PROCESS ROBUSTNE

41、SS EXPECTATIONS The molder shall demonstrate that its part design, mold, and molding process meet robustness criteria detailed in Appendix A. If one or more robustness criteria are not met, the molder should contact a Supplier Technical Assistance engineer who is responsible for either Tier one supp

42、lier or the molding supplier directly and consult a Ford subject matter expert for potential mitigating actions. 3.1 PART AND MOLD ROBUSTNESS The molder shall use a systematic approach to part design, mold design, and mold construction. The design process should include the following steps: Material

43、 selection Basic part design Structure analysis if applicable Part design review Printed Copies are Uncontrolled 9 of 52 Global Manufacturing Standards W-IMMS Control of Plastic Injection Molding Processes Third Edition Issued: 1-December-2015 Mold flow analysis Mold design Mold design review Mold c

44、onstruction follow-ups If responsible for part design, the molder shall verify material selection by using material data or benchmark to ensure that the material has the necessary chemical compatibility, material compatibility, temperature and humidity resistance, toughness and other physical and me

45、chanical properties to meet design intent unless otherwise specified by Ford engineering. The molder shall apply plastic part design principles and follow an applicable design standard or guidelines that are specified, recommended, or concurred by Ford Motor Company. At the minimum, the standard sha

46、ll include design details such as base wall thickness, radius, and draft angle etc The molder shall apply mold design knowledge and follow applicable mold design guidelines (internal or external) that are either recommended or concurred by Ford Motor Company. The molder shall conduct a benchmark stu

47、dy or run a preliminary mold flow simulation to determine initial size, shape and location of sprue, runner and gate for the mold. Unless deviation is agreed by Ford Motor Company, the molder shall use the knowledge obtained as inputs and conduct mold flow simulations to predict melt flow pattern, locations of knitline and