CAUSE OF OCCURANCE ( DEFECT WISE )

Qty QTY. OCC

DEFECT NAME CAUSE FOR OCCURANCE RATING PARETO CHART
Rejected PRODUCED RANKING

SHORT MOULDING Low hold on pressure low 11 357732 0.030749 2 0.16

0.153746379971599

Hot runner blocked 44 357732 0.122997 2

0.14

0.122997103977279
Injection speed low 55 357732 0.153746 2
0.12

Hot runner temperature low 5 357732 0.013977 2

0.1 0.089452439256203

Nozzle temperature low 8 357732 0.022363 2

0.072680106895665
0.08 0.069884718168909

Shot size less 25 357732 0.069885 2

0.06

Machine not calibrated during 357732 0.039135 2

14
0.039135442174589

0.04
0.03074927599432
power change over 357732 0 0.022363109814051

0.0139769436337820.013976943633782

Injection pressure low 5 357732 0.013977 2 0.02 0.011181554907025

0.002795388726756
0

Barrel temperature low 4 357732 0.011182 1 0

Startup part mixup with finished parts 1 357732 0.002795 1

Core cavity not matching in mould 32 357732 0.089452 2

Switch over position is less 26 357732 0.07268 2

PIN MARK hold on speed high 5 357732 0.013977 2

0.396945199199401

0.4

cavity gate blockage 8 357732 0.022363 2 0.35

0.3

sim loose 25 357732 0.069885 2 0.25

nozzle temperature high 31 357732 0.086657 2 0.2

0.15

ejector plate bend 142 357732 0.396945 2

0.097838605436472
0.086657050529447
0.069884718168909
0.1
0.041930830901345

Catching in mould 15 357732 0.041931 2 0.022363109814051

0.05 0.013976943633782

Material problem 35 357732 0.097839 2 1 2 3 4 5 6 7

BURN MARK air vent problem 23 357732 0.064294 2 0.064293940715396

0.07

injection speed high 10 357732 0.027954 2 0.06

0.05
0.027953887267564
0.04

0.03

0.02

0.01

1 2

WELD LINE MTC temp low 6 357732 0.016772 2 0.016772332360538

0.018

Air vent not give 2 357732 0.005591 1 0.016

0.014
0.012
0.01 0.005590777453513
0.008
0.006
0.004
0.002
0

1 2

STRESS MARK wrong handling of material at 159 450139 0.353224 2 0.353224226294545

the time of loading, unloading

0.4
0.4
0.2
0.2

00

and packing
Ejector force high 19 450139 0.042209 2

SINK MARK Mix up of initial parts 42 357732 0.117406 2 0.117406326523766

0.12

Catching in bosses 10 357732 0.027954 2 0.1

0.08

0.06 0.027953887267564

0.04

0.02

1 2

OIL MARK Oil leakage from hydraulic pipe 10 357732 0.027954 2 0.027953887267564

0.03

Mould undercuts not cleaned properly 3 357732 0.008386 1 0.025

0.02
0.008386166180269
0.015

0.01

0.005

1 2

SILVER STREAKS Nozzle heater not working 60 357732 0.167723 2 0.18

0.167723323605381

Hopper drier temp less 22 357732 0.061499 2 0.16

0.14

Material drying time is less 27 357732 0.075475 2 0.12

0.100633994163228

0.1
0.075475495622421
 CAUSE OF OCCURANCE ( DEFECT WISE )

0.167723323605381
0.18

Qty QTY. OCC

0.16

DEFECT NAME CAUSE FOR OCCURANCE RATING PARETO CHART

Rejected PRODUCED RANKING 0.14

0.12
0.100633994163228

0.1

Material predrying temp low 36 357732 0.100634 2 0.08

0.075475495622421

0.06149855198864

suck back more 5 357732 0.013977 2 0.06

0.04 0.022363109814051

Empty hopper 4 357732 0.011182 2

0.013976943633782
0.011181554907025
0.02

Hot runner temperature high 8 357732 0.022363 2 1 2 3 4 5 6 7

FLOW MARK Hot runner temperature high 32 357732 0.089452 2 0.3

0.25997115158834

Hopper throat temperature high 25 357732 0.069885 2 0.25

0.195677210872944

Injection speed high 93 357732 0.259971 2

0.2

0.15

Nozzle temperature high 34 357732 0.095043 2 0.089452439256203

0.095043216709716

0.1 0.069884718168909

Injection speed low 15 357732 0.041931 2

0.041930830901345

0.05

Gate thickness more 70 357732 0.195677 2 0

1 2 3 4 5 6

BLACK SPOTS hopper not cleaned properly 61 357732 0.170519 2 0.170518712332137

0.14536021379133
0.18

nozzle blockage 52 357732 0.14536 2 0.16

0.14
0.12
0.1
0.036340053447833
0.08

material mix up 13 357732 0.03634 2

0.06
0.04
0.02
0

1 2 3

FLASH Core cavity not matching 98 357732 0.273948 2 0.273948095222122

0.3

Hot runner temperature high 10 357732 0.027954 2 0.25

0.2

0.15

0.1 0.027953887267564

0.05

1 2

Colour VARIATION 357732 0

Warpage Less cooling time 2 314379 0.006362 1

0.006361748081138

0.008

0.006

0.004

0.002

DIMENSION VARIATION 314379 0

CAUSE OF OCCURANCE Matrix From ( DEFECT WISE )

Qty QTY. OCC

Sr. No. DEFECT NAME CAUSE FOR OCCURANCE RATING
Rejected PRODUCED RANKING

SHORT MOULDING Low hold on pressure low 11 357732 31 2

Hot runner blocked 44 357732 123 2

Injection speed low 55 357732 154 2

Hot runner temperature low 5 357732 14 2

Nozzle temperature low 8 357732 22 2
12543147098

Shot size less 25 357732 70 2 0

Machine not calibrated during 357732 39 2

1 14
power change over 357732 0
Injection pressure low 5 357732 14 2
Barrel temperature low 4 357732 11 1

Startup part mixup with finished parts 1 357732 3 1

Core cavity not matching in mould 32 357732 89 2

Switch over position is less 26 357732 73 2

#DIV/0!

BURN MARK air vent problem 23 357732 64 2

injection speed high 10 357732 28 2

2 #DIV/0!

#DIV/0!

#DIV/0!
WELD LINE MTC temp low 6 357732 17 2

Air vent not give 2 357732 6 1

3 #DIV/0!

#DIV/0!
#DIV/0!
Scratch /Dent wrong handling of material 159 450139 353 2
at the time of loading, unloading #DIV/0!

4 During packing #DIV/0!

Ejector force high 19 450139 42 2

#DIV/0!
Shine Mark wrong handling of material 159 450139 353 2
at the time of loading, unloading #DIV/0!

5 During packing #DIV/0!

Ejector force high 19 450139 42 2

#DIV/0!

SINK MARK or Shrinkage Mix up of initial parts 42 357732 117 2

Catching in bosses 10 357732 28 2

6 #DIV/0!

#DIV/0!

#DIV/0!

OIL MARK Oil leakage from hydraulic pipe 10 357732 28 2

Mould undercuts not cleaned properly 3 357732 8 1

7 #DIV/0!

#DIV/0!
#DIV/0!

PIN MARK hold on speed high 5 357732 14 2

cavity gate blockage 8 357732 22 2

sim loose 25 357732 70 2
126751408

8 nozzle temperature high 31 357732 87 2 0

1234567

ejector plate bend 142 357732 397 2

Catching in mould 15 357732 42 2

CAUSE OF OCCURANCE Matrix From ( DEFECT WISE )

126751408

8 0

1234567

Qty QTY. OCC

Sr. No. DEFECT NAME CAUSE FOR OCCURANCE RATING
Rejected PRODUCED RANKING

Material problem 35 357732 98 2

SILVER Mark Nozzle heater not working 60 357732 168 2

Hopper drier temp less 22 357732 61 2

Material drying time is less 27 357732 75 2

167514208

9 Material predrying temp low 36 357732 101 2 0

1234567

suck back more 5 357732 14 2

Empty hopper 4 357732 11 2

Hot runner temperature high 8 357732 22 2

FLOW MARK Hot runner temperature high 32 357732 89 2

Hopper throat temperature high 25 357732 70 2

Injection speed high 93 357732 260 2

10 Nozzle temperature high 34 357732 95 2

Injection speed low 15 357732 42 2

Gate thickness more 70 357732 196 2

#DIV/0!

BLACK SPOTS hopper not cleaned properly 61 357732 171 2

nozzle blockage 52 357732 145 2

11 material mix up 13 357732 36 2

#DIV/0!

#DIV/0!

FLASH Core cavity not matching 98 357732 274 2

Hot runner temperature high 10 357732 28 2

12 #DIV/0!

#DIV/0!
#DIV/0!

Colour Mismatch 357732 0

#DIV/0!

13 #DIV/0!
#DIV/0!

#DIV/0!

Warpage Less cooling time 2 314379 6 1

#DIV/0!

14 #DIV/0!

#DIV/0!

#DIV/0!
Deformation or Bend Less cooling time 2 314379 6 1

Inproper Part Handling #DIV/0!

15 #DIV/0!
#DIV/0!

#DIV/0!

DIMENSION NG #DIV/0!
#DIV/0!

16 #DIV/0!

#DIV/0!

#DIV/0!