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Monitoring of production quality for plastic component

Article in MM Science Journal · September 2016

DOI: 10.17973/MMSJ.2016_09_201622

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 problematic situations prior to correction of already occurred
MONITORING OF situations [Dulebova 2014].
Prior to data collection for calculation of capability of indices it
PRODUCTION QUALITY FOR is inevitable to check the measurement system of the selected
quality character so that the achieved results correctly
PLASTIC COMPONENT represent the actual capability of the process [Valicek 2015].
The measurement system is a complete process of collection of
JOZEF DOBRANSKY1, FRANTISEK BOTKO 1, EVA VOJNOVA2 data on measurement, i.e. a set of operations, procedures,
1Technical University of Kosice, Faculty of Manufacturing measuring tools and other equipment, software, personnel
Technologies with a seat in Presov, Slovak Republic applied in assignment of numerical values to the measured
21st features [Michalik 2014]. Assessment of the measurement
Presov Tool Making Company, Lubotice, Slovak Republic
system quality is performed on the basis of statistical
DOI: 10.17973/MMSJ.2016_09_201622 properties: bias in measurement, measurement congruity,
e-mail : [email protected] measurement repeatability measurement reproducibility,
Presented article is focused on monitoring of plastic measurement stability, and measurement linearity. The most
component production, which is used in automotive industry. significant elements of the measurement accuracy are
Quality of products depends on inspection of production compatibility and bias in measurement [Cidlina 2015].
process and thus is essential to use all available control Capability of the process refers to the process uniformity. Its
methods. Two methods were used for evaluation of output extent is usually represented by the process variability.
monitoring. First method is verification of measuring system Capability of the process is statistical measure of the inherent
capability, using measuring system analyze. Subsequently was variability of the process for the respective characteristics
assessed capability of manufacturing system through capability [Skumavc 2016].
index. Quality indicators were represented by dimensional The process capability measure has not been agreed on up to
characteristics of serial produced plastic component. Plastic present. At times the standard deviation σ or range of quality
molding was manufactured using plastic injection technology indicator or their multiple based upon the inherent variability
and is intended for lightening system in vehicles cargo space. are considered to be the capability measure. Occasionally, it is a
All documents for the monitoring capability was provided by combined value of the component induced by the inherent
LPH Vranov/T, Ltd. Article contain overall assessment of the variability and of the component induced by inconsiderable and
results and assess the overall capability of measuring and determinable causes [Kyas 2011].
production system.
KEYWORDS 2 DESCRIPTION OF EXPERIMENT
production, measuring system, quality indicators, injection
molding, capability Following figure (Fig.1) shows analyzed plastic molding used in
lightening system in vehicles cargo space. Component was
produced from material Dylac R H05, which is ABS material,
1 INTRODUCTION black colored granulate. Material properties of Dylac R H05 are
Quality and stability of the production processes are notions listed in table below (Tab. 1).
associated with the regulation procedures. In simple terms, the
stability refers to the fact whether the value prescribed during
input can be observed during output [Solfronk 2015].
In the very process of the series production of plastic moulded
pieces intended especially for automotive industry inevitable is
to check several indicators and parameters from material
reception through its processing and parameters of injection
process up to packing of the final products [Bobek 2016].
In current competition fight in the market the quality is
assessed as the preferred effective force focused on acquisition
or retaining of the market shares. The effective tool in
increasing of the quality is implementation of statistical
methods into the process which allow searching for the causes
of the process instability, regulate the efficiency and
effectiveness of the corrective actions, and stabilize the
development of the process by means of which the work
quality and productivity increase. It is obvious that the more
statistical methods are known, the higher the possibility of
analysis and of successful solving of a potential issue is
[Skotnicova 2014].
Statistical regulation of the SPC processes is the method of the
quality control applying the statistical methods. It is applied to
monitor and control the process. The regulation consists of two
phases: the first one refers to initial adjustment of
specifications of the selected process; the second one
represents the case of common process utilization in the Figure 1. Analyzed plastic molding
production. In comparison to other methods of the quality
control the advantage of application of the SPC method rests in
preference of timely detection and prevention of occurrence of

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 Characteristic Unit Value For customer: provide evidence that the product was produced
Density g/cm3 1.06 ± 0.03 in stable production conditions have been complied with and
Melt-volume flow rate MVR cm3/10min. 13 – 16 the prescribed quality criteria.
Charpy notched strength kJ/m2 ≥ 10 If Cp > 1.33 – process is capable.
Charpy impact strength kJ/m2 ≥ 70 If Cpk > 1.33 – pocess is capable and well centered (process is
Yield strength MPa ≥ 32 safe).
Yield strain % ≥ 2.4 If Cp < 1.33 – process is not capable.
Tensile strain at break % ≥ 20 If Cpk < 1.33 – process is not capable and not well centered
Vicat softening temperature °C ≥ 90 (process is not safe).
If Cp = 0 – average of process is located on tolerance boundary.
Water absorption % 1
If Cpk < 0 – average of process is located outside tolerance
Humidity absorption % 0.3
boundary.
Melt temperature °C 230
Mold temperature °C 60
Drying temperature °C 80 3 EVALUATION
Max. water content % ≤ 0.1 3.1 MSA - dimmension 1 (76,3 mm ± 0,3)
Table 1. Material properties of Dylac R H05 Measured values of dimension 1 are listed on Tab. 4. Tolerance
R&R is on value 4.96 % which indicates capability of
Measurements were performed using digital caliper with
measurement for this dimension. Critical value of this
measuring range 0 – 200 mm and linear altimeter with
coefficient is set on 10 %. In the fact of this can be stated that
measuring range 0 – 600 mm.
measuring system is acceptable.
Measuring consists of two phases:
 measurement for determination of measuring system
Repeatability Reproducibility
capability,
EV % EV Tol. % AV % AV Tol. %
 measurement for determination capability of
0.029 25.15 4.91 0.004 3.41 0.67
manufacturing system.
Repeatability & Reproducibility Part variation
Three dimensions were selected for determination capability, R&R % R&R Tol. % PV % PV Tol. %
which were measured by three operators A, B and C in three 0.029 25.38 4.96 0.11 96.7 18.9
cycles. Measured values of dimensions and tolerances are listed Total part variation 0.117
in Tab.2. Table 4. Final values for dimension 1

Dimmension Value [mm] Tolerance Graphical dependence (Fig. 2) represents range and average
1. 76.3 ± 0.3 values for dimension 1. Most precise measurements were
2. 48.6 ± 0.1 performed by operator C and A in range 0.010, measurements
performed by operator B were in range 0.010 and in once case
3. 60.3 ± 0.5
0.030.
Table 2. Measured values

After measuring of selected dimensions, by all three operators,

for all moldings can be done calculations of capability
coefficients. In subsequence is possible to create graphical
dependences of average values.
Repeatability and reproducibility is evaluated for all dimensions
which lead to evaluation of measuring system capability.
Evaluation of measuring system capability is performed
according to repeatability and reproducibility tolerance R&R
shown in Tab. 3.

< 10 % measurement system is acceptable

measurement system can be acceptable
10 - 30 % according to significance of application,
measuring tool costs, repair costs
measurement system is unacceptable and it
> 30 %
must be improved
Table 3. Assessment criterion of acceptability of the measuring tools

In second phase is capability of manufacturing system

evaluated based on capability indexes Cp and Cpk. In this phase
were performed fifty measurements of all three dimensions Figure 2. Graph of range and average values for dimension 1
from all molds cavity.

Significance of capability indexes: 3.2 MSA – Dimmension 2 (48,6 mm ± 0,1)

For producer: background for probability estimation of Similar as previous dimension is highlighted in Tab. 5 tolerance
occurrence of nonconforming products, preventive and of R&R. This tolerance is on value 8.59 %, which means that for
corrective actions, and assessment with regard to the efficacy this dimension measurement system is acceptable.
assessment process stability etc.

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 Repeatability Reproducibility
EV % EV Tol. % AV % AV Tol. %
0.016 20.07 8.13 0.005 6.86 2.78
Repeatability & Reproducibility Part variation
R&R % R&R Tol. % PV % PV Tol. %
0.017 21.2 8.59 0.079 97.72 39.6
Total part variation 0.081
Table 5. Final values for dimension 2

Graphical dependence (Fig. 3) represents range and average

values for dimension 2. Measurements of dimension 2 were not
as precise as for dimension 1. Measured values reached higher Figure 4. Graph of range and average values for dimension 3
value of range. For operators A, B is range on value 0.010 and
for operator C 0.060. Tolerance limit was not exceeded. Tolerance limit (UCL) on value 0.017 was not exceded for
dimension 3. Most of values lies in range 0.010 (six for operator
A and seven for operator B and C).

3.4 Capability of process - Dimension (76.3 mm ± 0.3)

Values of capability index for dimension 1 are listed in Tab.7. Cp
for dimension 1 is for all cases above value 1.33, which
indicates good capability from Cp point of view. Cpk index
reaches high value what represents that process is well
centered (Fig. 5).

Max. Min. Average

St. dev. Cp Cpk
value value value
Cavity 1 76.19 76.17 76.180 0.0076 13.229 7.937
Cavity 2 76.23 76.20 76.214 0.0093 10.801 7.705
Cavity 3 76.20 76.18 76.192 0.0080 12.548 8.048
Cavity 4 76.22 76.19 76.207 0.0076 13.210 9.124
Cavity 5 76.23 76.21 76.217 0.0070 14.265 10.328
Cavity 6 76.16 76.14 76.150 0.0077 12.983 6.491

Table 7. Values of capability indexes for dimension 1

Due to similarity between each cavity values, only one

histogram for cavity 1 was created (Fig. 5). Graphical
representation shows process lies in tolerance limits and is well
Figure 3. Graph of range and average values for dimension 2 centered.

3.3 MSA – Dimmension 3 (60,3 mm ± 0,5)

R&R value is on value 21.95 % which results to capability
tolerance on value 2.06 %. Capability tolerance under 10 %
represents that measurement system for selected dimension is
acceptable.

Repeatability Reproducibility
EV % EV Tol. % AV % AV Tol. %
0.020 21.6 2.03 0.003 3.83 0.36
Repeatability & Reproducibility Part variation
R&R % R&R Tol. % PV % PV Tol. %
0.020 21.95 2.06 0.091 97.5 9.18
Total part variation 0.094
Figure 5. Graphical representation of manufacturing system capability
Table 6. Final values for dimension 3 for dimension 1 (cavity 1)

3.5 Capability of process - Dimmension 2 (48.6 mm ± 0.1)

Values of capability index for dimension 2 are listed in Tab.8.
Max. Min. Average
St. dev. Cp Cpk
value value value
Cavity 1 48.7 48.68 48.693 0.0077 4.342 0.295
Cavity 2 48.7 48.68 48.692 0.0080 4.183 0.318
Cavity 3 48.7 48.68 48.693 0.0075 4.440 0.329
Cavity 4 48.7 48.68 48.692 0.0068 4.895 0.411
Cavity 5 48.7 48.68 48.695 0.0065 5.156 0.268
Cavity 6 48.7 48.68 48.691 0.0081 4.124 0.355

Table 8. Values of capability indexes for dimension 2

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 Cp for dimension 2 is for all cases above value 1.33, which system capability was performed. Each dimension complied for
indicates good capability from Cp point of view. Cpk index tolerations repeatability and reproducibility (for all cases lower
shows that process is not well centered in relation to nominal than 10 %). Subsequently was evaluated capability of
value (Fig. 6). manufacturing process. For this capability compiled all
Graphical representation shows that median of measured dimensions, with exception of dimension 48.6 mm ± 0.1. In this
values is offset from nominal value on the limit USL (which was case according to Cp was system capable with low range of
indicated by Cpk index). values. Verification using Cpk index proved that process is not
well centered, which leads to examining and rectification of
system.

ACKNOWLEDGMENT
The research work was supported by project VEGA 1/0381/15.

REFERENCES
[Bobek 2016] Bobek, J. et al. New silane and MAPP coupling
agents as natural composites production systems
improvement, Key Engineering Materials, 2016, Vol. 669, pp.
52-59. ISSN 1013-9826.
[Cidlina 2015] Cidlina, J., Müller, M. Influence of adhesive
bonded surface treatment of alloy AlCu4Mg and increased
environmental temperature on adhesive bond strength.
Figure 6. Graphical representation of manufacturing system capability
Manufacturing Technology, 2015, Vol. 15, No. 4, pp. 520-526.
for dimension 2 (cavity 6)
ISSN 1213-2489.
3.6 Capability of process - Dimension 3 (60.3 mm ± 0.5) [Dulebova 2014] Dulebova, L. et al. Characterization of
Cp index is above 1.33 which indicates good capability of mechanical and thermal properties of pp/mineral composites.
process. Cpk index is also above 1.33. In the fact of this can be Advanced Materials Research, 2014, Vol. 1025-1026, pp. 241-
stated that process is capable and well centered. 245. ISSN 1022-6680.
[Kyas 2011] Kyas, K. et al. Simulation of rubber injection
Max. Min. Average molding process. Chemicke Listy, 2011, Vol. 105, No. 15 SPEC.
St. dev. Cp Cpk ISSUE, pp. s354-s356. ISSN 0009-2770.
value value value
Cavity 1 60.34 60.33 60.335 0.0050 33.025 30.700 [Michalik 2014] Michalik, P. et al. Monitoring surface
Cavity 2 60.31 60.29 60.298 0.0083 20.193 20.120 roughness of thin-walled components from steel C45 machining
Cavity 3 60.31 60.30 60.307 0.0045 36.747 36.217 down and up milling. Measurement, 2014, Vol. 58, pp. 416-428.
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Cavity 6 60.21 60.19 60.199 0.0079 21.125 16.858 crystallization conditions on tantalum distribution in
Table 8. Values of capability indexes for dimension 3 molybdenum and tungsten during electron beam zone melting.
Metalurgija, 2014, Vol. 53, No. 2, pp. 209-211. ISSN 0543-5846.
Similar capability indexes causes proximity for values in [Skumavc 2016] Skumavc, A. et al. Thermal fatigue study of
histogram. Normal distribution lies in narrow interval near tungsten alloy WNi28Fe15 cladded on AISI H13 hot work tool
nominal value Fig. 7. steel. Surface and Coatings Technology, 2016, Vol. 285, pp. 304-
311. ISSN 0257-8972.
[Solfronk 2015] Solfronk, P. et al. Influence of deformation on
the damage of zn-mg based protective coating. Materials
Science Forum, 2015, Vol. 818, pp. 57-60. ISSN 0255-5476.
[Valicek 2015] Valicek, J. et al. Quantifying the Mechanical
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CONTACTS
Ing. Jozef Dobransky, PhD.
Technical University of Kosice
Figure 7. Graphical representation of manufacturing system capability Faculty of Manufacturing Technologies with a seat in Presov
for dimension 3 (cavity 3) Bayerova 1, Presov, 08001, Slovak Republic
Tel.: +421 55 602 6337
e-mail: [email protected]
4 CONCLUSION www.tuke.sk/fvtpo
Measurements from three dimension of the molding
manufactured in LPH Vranov n/T Ltd. were numerically and
graphically evaluated. In first part evaluation of measurement

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