Ethiopian Institute of Technology –

Mekelle University [Eit-M]

Department Of Chemical Engineering

Internship Report at Fasil Berhane Manufacture of

Tire & Plastic Products

Name: Mahlet Atakilti Negash

Id: Eit-M/Ur157840/11
Section: 3

Submitted To – Department Of Chemical

Engineering
Submission Date – ______________________________
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ETHIOPIAN INSTITUTE OF TECHNOLOGY – MEKELLE UNIVERSITY [EIT-

M]
DEPARTMENT OF CHEMICAL ENGINEERING

DECLARATION

All material and works I presented on this report is my own unaided work done
by me under the guidance of Mr. Fasil Berhane. And this project work is
submitted in the partial fulfillment of the requirements for the internship session
of 2016 E.C. held of 4th year 2nd semester student of Ethiopian Institute Of
Technology – Mekelle University [Eit-M] Chemical Engineering Department.

I hereby declare that I have submitted this report to the Faculty of Ethiopian
Institute Of Technology – Mekelle University [Eit-M] at Mekelle University as a
partial fulfillment of the requirements for the completion of my internship.

Approved by

 Name of Supervisor _________________________

Signature ________________________

Hosting Company Stamp

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ACKNOWLEDGEMENT

On behalf of this internship program,

First and foremost, I express my deepest gratitude to the Almighty God for
granting me the strength and determination to pursue my goals and then my
family for helping me through thick and thin since I was a child.

I am thankful to Ethiopian Institute Of Technology – Mekelle University [Eit-M]

Internship Coordination Office for providing me with the opportunity to gain
practical education, enabling me to acquire valuable experience and
understanding of the real world.

I extend my sincere appreciation to Fasil Berhane Manufacture of Tire & Plastic

Products for their warm welcome and the opportunity to study and work with
them. Additionally, I would like to thank the dedicated staffs and management
team for their invaluable knowledge sharing and support.

Lastly, I am grateful to my mentor, Mr. Fasil Berhane his guidance during the
internship program.

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ABSTRACT

Education is widely acknowledged as the lifeline of humanity and the most

powerful tool available to anyone seeking success in various domains. Because
of its success, Ethiopian Institute Of Technology – Mekelle University [Eit-M]
Internship Coordination Office offers its students a high standard of education by
incorporating various hosting companies. Additionally, this internship is a helpful
way for us to apply what we have learned in the classroom to real-world
situations. In this report, I've covered the firm's (Fasil Berhane Manufacture of
Tire & Plastic Products) background and profile as well as the lessons I acquired
from working there and from watching others. I made every effort to understand
as much as I could about this field's applications. I Attempt to provide a succinct
and accurate summary of my two months of internship experience. Also, a brief
explanation of each chapter's topic is provided.

A brief history of the organization (Fasil Berhane Manufacture of Tire & Plastic
Products) is provided in the first chapter, along with information about the
company's goals, vision, and services provided, as well as its official address.

The second chapter goes into the resources and techniques I've employed over
the course of the last two months.

The third chapter detailed the total project I worked on for my internship
throughout the course of the five months. This is the primary chapter where I
document all of the work I have been doing, along with a concise and thorough
explanation.

As we approach the fourth chapter, I attempt to clarify the primary benefit of

the internship experience in relation to several factors. It is well recognized that
an internship allows a graduate or advanced student in a professional discipline
to obtain supervised real-world experience in a business or industry.

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This report's final section is devoted to its conclusions and suggestions.

Suggestions and recommendations are generally well-thought-out and pertinent
for both the progress of the course and incoming students.

TABLE OF CONTENT

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Cover Page

DECLARATION........................................................................................................................................2

ACKNOWLEDGEMENT..........................................................................................................................3

ABSTRACT................................................................................................................................................4

TABLE OF CONTENT.............................................................................................................................5

CHAPTER ONE........................................................................................................................................9

1. Background of hosting Company............................................................................................9

1.1. Introduction.................................................................................................................................9

1.2. Background of the company...............................................................................................10

1.3. Objectives of the company..................................................................................................10

1.3.1. General Objectives:........................................................................................................10

1.3.2. Specific Objectives related to Tire Production:.....................................................11

1.3.3. Sustainability-Focused Objectives:...........................................................................11

1.4. Mission of the Company:......................................................................................................11

1.5. Vision of the company:.........................................................................................................12

1.6. End products and service of the company.....................................................................12

Plastic Products:..............................................................................................................................12

Services:.............................................................................................................................................13

Possible Future Expansion:..........................................................................................................13

1.7. Reference of Plastic Products and experience of the company.............................14

1.7.1. Home Goods......................................................................................................................14

1.7.2. Water Tanks......................................................................................................................14

1.7.3. PVC.......................................................................................................................................15

1.7.4. Rope.....................................................................................................................................16

1.7.5. Drums and Barrels..........................................................................................................18

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1.7.6. Jerrycans.............................................................................................................................19

1.7.7. Bucket.................................................................................................................................19

1.8. The main customers or end users.....................................................................................20

Plastic Products:..............................................................................................................................20

Additional Considerations:...........................................................................................................20

1.9. Over all organizational structure and work flow..........................................................21

1.9.1. Man Power.........................................................................................................................22

1.9.2. Scope of Services............................................................................................................23

Company Address...........................................................................................................................24

CHAPTER TWO.....................................................................................................................................25

2. PROCESS TECHNOLOGY OF THE FACTORY........................................................................25

2.1. Materials.................................................................................................................................25

2.2. Process Technology............................................................................................................25

Step 1. Material Preparation and Handling............................................................................26

Step 2: Design and Mold Preparation......................................................................................27

Step 3. Injection Molding Process.............................................................................................28

Step 4: Mold Opening and Ejection...........................................................................................28

Step 5. Post-Molding Operations...............................................................................................29

Step 6. Inspection and Quality Control....................................................................................29

Step 7. Packaging and Shipping................................................................................................30

Additional Considerations for Recycled Plastics:.................................................................30

CHAPTER THREE:.................................................................................................................................31

3. OVERALL INTERNSHIP EXPERIENCE......................................................................................31

3.1. Section of the company you have been working.....................................................32

3.2. The work flow of the section..............................................................................................34

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3.3. The work piece or work task that you have been executed...................................36

3.4 The procedures and methods you have been used....................................................37

3.5 The challenges that you have been faced while performing your task...............39

3.6 The measures to overcome the challenge.....................................................................40

CHAPTER FOUR:...................................................................................................................................42

4. OVER ALL BENEFIT FROM THE INTERNSHIP.......................................................................42

4.1. In terms of upgrading theoretical knowledge...............................................................43

4.2. In terms of improving practical skills...............................................................................43

4.3. In terms of industrial problem solving capability.........................................................43

4.4. In terms of improving team playing skills......................................................................43

4.5. In terms of improving leadership skills............................................................................44

4.6. In terms of work ethics related issues.............................................................................44

4.7. In terms of entrepreneurship skills...................................................................................44

4.8. In terms of improving interpersonal skills......................................................................44

CHAPTER FIVE......................................................................................................................................45

5. CASE STUDY PROJECT................................................................................................................45

5.1. Short summery........................................................................................................................46

5.2. Introduction...............................................................................................................................46

5.3. Problem of Statement............................................................................................................46

5.4. Objectives..................................................................................................................................47

5.4.1. General Objective:..........................................................................................................47

5.4.2. Specific Objectives:........................................................................................................47

5.5. Scope of the Project...............................................................................................................48

5.6. Literature Review....................................................................................................................50

5.6.1. What is Statistical Process Control (SPC)?..............................................................50

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5.6.2. Data Collection for SPC.................................................................................................51

5.6.3. SPC Charts.........................................................................................................................52

What is a Control Chart?...............................................................................................................52

5.6.4. Statistical Process Control (SPC) for Injection Molding......................................57

5.6.5. Benefits of SPC in Injection Molding:........................................................................58

5.6.6. Common SPC Methodologies in Injection Molding:.............................................58

5.6.7. Challenges of Implementing SPC:.............................................................................59

5.7. Methodology.............................................................................................................................59

5.7.1. Material Balance..............................................................................................................60

5.7.1.1. Key Success Factors:..................................................................................................60

5.7.1.2. Benefits of SPC for Material Balance:...............................................................60

5.7.2. Energy Balance................................................................................................................60

5.7.2.1. Key Success Factors:..............................................................................................60

5.7.2.2. Benefits of SPC for Energy Balance:.................................................................61

5.7.3. Equipment Sizing.............................................................................................................61

5.7.3.1. Key Success Factors:..............................................................................................61

5.7.3.2. Benefits of SPC for Equipment Sizing:.............................................................62

5.8. Environmental Considerations in SPC Implementation for Injection Molding....62

5.9. Results and Discussion: Implementing SPC in Injection Molding...........................65

5.9.1. Results:...............................................................................................................................65

5.9.2. Discussion:.........................................................................................................................66

5.10. Conclusion and Recommendations...............................................................................67

5.10.1. Conclusion:........................................................................................................................67

5.10.2. Recommendations:.........................................................................................................68

CHAPTER SIX.........................................................................................................................................69

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6. Overall Conclusion and Recommendations.......................................................................69

6.1. Conclusion:................................................................................................................................69

6.2. Recommendations:.................................................................................................................70

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CHAPTER ONE

1. Background of hosting Company

1.1. Introduction

Fasil Berhane Manufacture of Tire & Plastic Products is a company built on a

foundation of quality, innovation, and unwavering commitment to customer
satisfaction. They are a leading manufacturer of a wide range of tire and plastic
products, serving diverse sectors with reliable and durable solutions.

Their dedication to cutting-edge technology and stringent quality control

ensures that every product they produce meets the highest industry standards.
Whether it's the robust tires for heavy-duty vehicles or the versatile plastic
products for everyday use, the company prioritizes performance and longevity.
And they are committed to sustainable practices and strive to minimize our
environmental impact throughout the entire manufacturing process.

1.2. Background of the company

General

Fasil Berhane Manufacture of Tire & Plastic Products is a well-known private

plastic manufacturing company in Addis Ababa, Ethiopia. They are a
manufacturer of plastic home goods, water tanks, PVC pipes, plastic boots
shoes and many more.

General Manager

Fasil Berhane, the namesake and General Manager of Fasil Berhane

Manufacture of Tire & Plastic Products, embodies the spirit of the company
itself: a blend of tradition, innovation, and unwavering dedication to quality.

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Fasil's journey began with a deep passion for manufacturing and a strong belief
in the power of industry to drive progress. His early experience instilled in him a
strong work ethic, a keen understanding of the manufacturing process, and a
commitment to excellence that has become the foundation of Fasil Berhane's
success.

As General Manager, Fasil Berhane is a visionary leader who constantly pushes

the company to evolve and innovate. He is deeply involved in all aspects of the
business, from product development to strategic planning, ensuring that Fasil
Berhane remains at the forefront of the tire and plastic manufacturing industry.

1.3. Objectives of the company

Fasil Berhane Manufacture of Tire & Plastic Products, keeping in mind the start
of their tire production:

1.3.1. General Objectives:

• To establish a leading position in the tire and plastic products market

through innovation, quality, and customer satisfaction.
• To achieve sustainable and profitable growth by expanding product lines
and market reach while maintaining ethical business practices.
• To create a safe and fulfilling work environment for employees, fostering a
culture of continuous learning and development.

1.3.2. Specific Objectives related to Tire Production:

• To achieve a successful launch of tire production, meeting targeted

production volumes and quality standards within a specified timeframe.
• To optimize the tire manufacturing process for maximum efficiency,
minimizing waste and maximizing resource utilization.
• To develop a robust quality control system that ensures consistent
product quality and meets customer expectations.

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• To establish a strong market presence for Fasil Berhane's tire products,

building brand recognition and customer loyalty.

1.3.3. Sustainability-Focused Objectives:

• To minimize the environmental impact of tire production through waste

reduction, resource efficiency, and responsible disposal practices.
• To prioritize the use of sustainable materials and manufacturing processes
whenever possible.
• To promote ethical and responsible sourcing practices throughout the
supply chain.

1.4. Mission of the Company:

To provide reliable, durable, and environmentally responsible tire and plastic

products that meet the diverse needs of our customers while fostering long-term
partnerships built on trust and mutual success.

1.5. Vision of the company:

To be the leading manufacturer of high-quality, innovative tire and plastic

products, recognized for its commitment to customer satisfaction and
sustainable practices.

Values:

 Quality: “We are committed to delivering products that meet the highest
industry standards and exceed customer expectations.
 Innovation: We embrace technological advancements and strive to
continuously improve our products and processes.
 Customer Focus: We prioritize understanding our customers' needs and
providing personalized solutions and exceptional service.

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 Sustainability: We strive to minimize our environmental impact through

responsible practices and the development of eco-friendly products.
 Integrity: We conduct our business with honesty, transparency, and
ethical principles.
 Collaboration: We foster a culture of teamwork and open
communication, empowering our employees to contribute to our success.

These values guide every decision we make and every action we take at Fasil
Berhane. They are the foundation of our success and the driving force behind
our commitment to providing excellence in everything we do.

1.6. End products and service of the company

Fasil Berhane Manufacture of Tire & Plastic Products could offer, considering
their focus on plastic products:

Plastic Products:
• Injection molded products: A wide variety of plastic components used
in various industries, including automotive, electronics, construction, and
consumer goods.
• Extrusion products: Plastic sheets, profiles, and tubes for applications in
packaging, building materials, and other industries.
• Blow molded products: Hollow plastic products like bottles, containers,
and tanks used in various sectors.
• Rotational molded products: Large, hollow plastic products such as
tanks, drums, and playground equipment.

Services:
• Custom manufacturing: Providing tailored solutions to meet specific
customer requirements for tire and plastic products.
• Product design and engineering: Offering expertise in product design,
development, and optimization for both tire and plastic products.

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• Technical support and consultation: Providing guidance and

troubleshooting assistance to customers regarding product selection,
usage, and maintenance.
• After-sales service: Offering repair, replacement, and warranty services
for tire and plastic products.

Possible Future Expansion:

• Recycled tire products: Developing and manufacturing products made
from recycled tires, promoting a circular economy.
• Bio-based plastic products: Exploring the use of renewable and
sustainable materials to manufacture plastic products.
• Advanced tire technologies: Focusing on the development of high-
performance, fuel-efficient tires with innovative features.

This list provides a foundation for understanding Fasil Berhane's potential

product and service offerings. The actual scope will depend on the company's
strategic direction, market opportunities, and manufacturing capabilities.

1.7. Reference of Plastic Products and experience of

the company

1.7.1. Home Goods

They producing vast range of house hold plastic items.

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1.7.2. Water Tanks

They produce different sizes of water tanks ranging from 300 liters to 10,000
liters.

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1.7.3. PVC

They produce PVC in an enormous range for both domestic and

industrial use

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1.7.4. Rope

They are producing ropes length of 100 and 200 with thickness ranging
from 4 to 24.

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1.7.5. Drums and Barrels

They produce barrels from 1ltr to 100ltr and drums from 80ltr to 300ltr
in different shapes and style

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1.7.6. Jerrycans

They are producing Jerrycans from 1 Liter to 30 Liters.

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1.7.7. Bucket

We are producing from 3 liters to 120 liters of buckets with different colors as
well as thicknesses.

1.8. The main customers or end users

Here are some potential main customers or end users for Fasil Berhane
Manufacture of Tire & Plastic Products, considering their plastic production:

Plastic Products:

• Automotive industry: Manufacturers of cars, trucks, and other vehicles

using plastic components in various parts like dashboards, bumpers, and
interior trim.
• Electronics industry: Companies that use plastic for housing,
enclosures, and other components in consumer electronics, computers,
and industrial equipment.
• Construction industry: Manufacturers of building materials, pipes, and
other construction components utilizing plastic for its durability,
insulation, and lightweight properties.
• Consumer goods industry: Companies that manufacture a wide range
of consumer products, including toys, furniture, appliances, and
packaging, all relying on plastic for various components.

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• Industrial manufacturers: Various industries requiring plastic for

specific applications, such as chemical processing, food packaging, and
agricultural equipment.

Additional Considerations:

• Target market segmentation: Fasil Berhane may choose to focus on

specific segments within these broad categories. For example, they could
specialize in high-performance tires for racing or high-end vehicles, or
they could target specific industries for their plastic products.
• Geographic market: Depending on their manufacturing capacity and
logistical capabilities, they might prioritize sales within a specific region or
country.
• Export markets: If Fasil Berhane wants to expand its reach, they could
explore exporting their tires and plastic products to other countries.

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1.9. Over all organizational structure and work flow

The team is organized in four operational sections namely: Raw Material

Sourcing & Quality Control, Production & Manufacturing, Packaging &
Distribution and Finance and Administration.

General
Manager

Raw Material
Production & Finance and
Sourcing & Packaging &
Manufacturin Administratio
Quality Distribution
g n.
Control,

Tire
Manufacturin
Sourcing g Packaging
(Opening
Soon)

Plastic
Initial
Manufacturin Distribution
Inspection
g

In-Process
Inspection

1.9.1. Man Power

Fasil Berhane Manufacture of Tire & Plastic Products recognizes that its human
capital is its most valuable asset. The company boasts a dedicated and skilled
workforce, comprised of Experienced Professionals, Skilled Workers, Quality
Control Specialists, Management & Support Staff, and Safety & Welfare.

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This dedicated and skilled workforce is the backbone of Fasil Berhane's success.
Their commitment to excellence, coupled with the company's investment in
their development, ensures that Fasil Berhane continues to produce high-quality
products and provide exceptional service to its customers.

1.9.2. Scope of Services

Plastic Products:

• Custom plastic molding: they specialize in custom plastic molding for a

wide range of applications. We utilize advanced molding techniques and
high-quality plastic materials to produce precise and durable plastic
components.

• Plastic fabrication: They offer comprehensive plastic fabrication

services, including cutting, drilling, welding, and assembly. We can create
customized plastic parts and products according to your specific
specifications.

• Plastic recycling: They offer plastic recycling services, contributing to a

sustainable and environmentally friendly approach. We process and
recycle various types of plastic waste, transforming it into valuable
materials for reuse.

Additional Services:

 Product design and development: They offer product design and

development services for plastic products.
 Quality control: They maintain strict quality control measures
throughout their production process to ensure that all products meet the
highest standards of excellence.
 Delivery and logistics: They offer reliable delivery and logistics
services, ensuring that your products are delivered on time and in perfect
condition.

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Target Market:

They serve a wide range of clients, including:

 Industrial businesses
 Agricultural businesses.
 Retailers:
 Government agencies:

Company’s Commitment:

At Fasil Berhane Manufacture of Tire & Plastic Products, They are committed to:

 Customer satisfaction: Strives to exceed customers’ expectations by

providing high-quality products and exceptional customer service.
 Innovation: They continuously invest in research and development to
offer innovative and cutting-edge solutions.
 Sustainability: They are committed to responsible environmental
practices and promote sustainable solutions.

Company Address

Fasil Berhane Manufacture of Tire & Plastic Products

Head office: Kara, Sebeta Road,
Kolfe Keranio Sub-city, Woreda 02/03, House Room No.
104
Mobile: 0930003450
Postal office PO Box 5/1110
Addis Ababa, Ethiopia
General Manager Fasil Berhane

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Mobile: +251 930003450

E-mail and web E-mail: fb.plasticcompany@gmail.com
Web: Under formation

CHAPTER TWO

2. PROCESS TECHNOLOGY OF THE FACTORY

Fasil Berhane Manufacture utilizes injection molding as a primary plastic

processing method. They are equipped with WELLTEC INJECTION MOULDING
MACHINES, known for their high output, speed, energy efficiency, and precision.
These machines enable the production of a wide range of plastic components
with varying sizes and complexities.

Plastic injection molding is a complex and precise manufacturing process that

transforms raw plastic material into a wide range of products with intricate
shapes and precise dimensions.

2.1. Materials

The company processes both virgin and recycled plastic materials, reflecting
their commitment to sustainable practices. This allows them to offer a wider
range of product options and potentially reduce their environmental impact.
Here's a breakdown of their material use:

• Virgin Plastics:

 Polyethylene (PE)
 Polypropylene (PP)
 Polyvinyl Chloride (PVC)
 Acrylonitrile Butadiene Styrene (ABS)

• Recycled Plastics:

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 The specific types of recycled plastics they use will depend on their
sourcing and their product applications. It's common to use recycled
versions of the virgin plastics listed above.

2.2. Process Technology

Here are the key steps involved in the plastic process technology at Fasil
Berhane Manufacture, focusing on their injection molding process using both
virgin and recycled plastics:

Step 1. Material Preparation and Handling

• Sourcing: Fasil Berhane obtains both virgin and recycled plastic

materials from reputable suppliers.

• Material Inspection: Incoming materials are inspected to ensure they

meet the required quality standards, including checking for
contamination, moisture content, and particle size.

• Storage: Materials are stored in appropriate conditions to maintain their

properties and prevent degradation.

• Material Blending: Depending on the specific product requirements,

virgin and recycled plastics may be blended to achieve the desired
performance characteristics.

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Figure : Blender/Mixer/ machine

Step 2: Design and Mold Preparation

Designing the mold is one of the most critical steps in the injection molding
process. This is where the magic begins! The mold, often made from hardened
steel, pre-hardened steel, aluminum, or beryllium-copper alloy, is precision-
machined to form the features of the desired part.

 Product Design: The process begins with a detailed product design or

concept. Design considerations include functionality, aesthetics, material
selection, and manufacturability.
 Mold Design: A mold, also known as a tool or die, is created based on
the product design. The mold consists of two halves – the cavity and the
core – that create the shape of the final product.

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 Material Selection: Choose the appropriate plastic material based on

the product’s requirements, considering factors like mechanical
properties, chemical resistance, and temperature stability.
 Mold Fabrication: Skilled toolmakers manufacture the mold using
precision machining techniques. The mold’s complexity and size influence
the time and cost of fabrication.

Figure: Mold

Step 3. Injection Molding Process

The injection of molten plastic into the mold. The plastic pellets are fed into the
hopper of the injection molding machine where they are heated until they
become molten. This molten plastic is then injected into the mold cavity under
high pressure.

The injection process is a critical stage in the injection moulding process. It

requires precise control over the temperature and pressure to ensure the
molten plastic fills the entirety of the mold and captures all the fine details of
the part design.

• Clamping: The mold is mounted onto the injection molding machine. The
two halves are securely closed using hydraulic or mechanical force to
ensure proper alignment.

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• Injection: Plastic pellets, known as resin, are fed into the injection
molding machine’s hopper. The pellets are heated and melted within the
barrel to a consistent molten state.

• Injection Pressure and Speed: The molten plastic is injected into the
mold’s cavity under high pressure. The injection speed and pressure are
controlled to fill the mold and prevent defects like voids or sink marks.

• Cooling: After the mold is filled, the plastic inside begins to cool and
solidify. Cooling time is carefully controlled to achieve the desired part
quality.

• Holding Pressure: Some molds include holding pressure to compensate

for material shrinkage during cooling. This ensures the part retains its
shape and dimensions.

Step 4: Mold Opening and Ejection

• Cooling Completion: Once the molten plastic has been injected into the
mold, it begins to cool and solidify. This cooling process is crucial as it
allows the plastic to harden into the shape of the mold, forming the final
part.
During this stage, the plastic undergoes a transformation from a hot,
flowing material to a solid, rigid part. The cooling rate must be carefully
controlled to avoid warping or shrinkage of the part. Once the part has
fully solidified, the mold can be opened, ready for the next stage of the
process.

• Ejection: With the cooling process complete, it’s time for the birth of a
new component. The clamping unit of the injection molding machine
opens, and the newly formed part is ejected from the mold. This is done
using ejector pins which push the part out of the mold.
Ejection might seem like a simple step, but it’s crucial to get it right. If the
part is ejected too forcefully or too soon (before it has fully cooled and
solidified), it could be damaged or deformed. On the other hand, if the

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part sticks to the mold, it could be difficult to remove and slow down the
entire process.

Step 5. Post-Molding Operations

• Trimming: Any excess plastic is trimmed from the molded part using a
trimming tool.

• Deburring: Sharp edges or burrs on the molded part are removed.

• Cleaning: The molded parts are cleaned to remove any debris or

contaminants.

Step 6. Inspection and Quality Control

The final step in the injection moulding process is inspection and quality control.
Each part is carefully examined to ensure it meets the required specifications
and quality standards. This might involve checking the dimensions of the part,
examining its surface finish, and testing its mechanical properties.

Quality control is a critical part of the injection moulding process. It ensures that
each part produced is up to standard and fit for its intended use. If a part
doesn’t pass inspection, it’s a sign that something in the process needs to be
adjusted, whether it’s the design of the mold, the settings of the machine, or the
choice of material.

• Dimensional Inspection: The molded parts are inspected for

dimensional accuracy to ensure they meet the specifications.

• Visual Inspection: Molded parts are visually inspected for defects,

including surface blemishes, sink marks, and weld lines.

• Material Property Testing: Selected parts are subjected to material

property testing to verify their tensile strength, impact resistance, and
other required characteristics.

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Step 7. Packaging and Shipping

• Packaging: Molded parts are packaged to prevent damage during

shipping.

• Shipping: The packaged products are shipped to customers or

wholesalers.

Additional Considerations for Recycled Plastics:

• Recycling Process: Recycled plastics may require additional processing

steps to ensure they are compatible with the injection molding process.
This may involve sorting, cleaning, and grinding.

• Material Properties: Recycled plastics may have slightly different

properties than virgin plastics, so the molding process may need to be
adjusted.

• Quality Control: More rigorous quality control measures are often

employed for recycled plastics to ensure they meet the performance
standards.

This comprehensive breakdown of the plastic process technology at Fasil

Berhane Manufacture, considering both virgin and recycled plastics, provides a
clear understanding of their capabilities and operations.

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CHAPTER THREE:

3. OVERALL INTERNSHIP EXPERIENCE

As a 4th year and 2nd semester student, my journey into the world of internships
began with a touch of serendipity. It all started when my Husband, who always
had a knack for making unexpected connections, introduced me to Mr. Fasil
Berhane, the founder and CEO of Fasil Berhane Manufacture of Tire & Plastic
Products.

I remember the day vividly when my husband mentioned that he knew someone
who might be able to offer me an internship opportunity in a field I was
passionate about. Little did I know that this casual introduction would pave the
way for a significant chapter in my professional development.

Mr. Fasil Berhane, with his warm demeanor and passion for design, welcomed
me into his company with open arms. His enthusiasm for nurturing young
talents like myself was evident from the moment we met. I could sense the
excitement in the air as he shared the projects they were working on.

Joining the design team at Fasil Berhane Manufacture of Tire & Plastic Products
felt like a dream come true. The opportunity to learn from experienced
professionals in a dynamic work environment was both exhilarating and
humbling. As I embarked on this new chapter of my career, I knew that I was in
for a transformative experience that would shape my perspective on Chemical
engineering.

Looking back, I am grateful to my Husband for connecting me with Mr. Fasil

Berhane and his team at Fasil Berhane Manufacture of Tire & Plastic Products.
Their belief in my potential and their willingness to mentor me have been
invaluable in shaping my journey as an aspiring engineer. As I continue to
navigate the world of design, I carry with me the lessons learned during my

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internship – lessons of passion, dedication, and the power of meaningful

connections in shaping one's career path my path.

3.1. Section of the company you have been working

During my internship program at Fasil Berhane Manufacture of Tire & Plastic

Products I was posted on "Injection Molding Process Control team”. It is a more
specific and focused section within the broader Injection Molding Process. This
section emphasizes the critical role of controlling and monitoring the injection
molding process to ensure consistent product quality, optimize production
efficiency, and minimize waste.

Here's a more detailed breakdown of the Injection Molding Process Control

section:

Key Responsibilities:

• Monitoring and Controlling Production Parameters: This includes

carefully adjusting and maintaining key variables like injection pressure,
temperature, cycle time, mold clamping force, and material flow rate. This
ensures the consistent production of high-quality products while
minimizing defects and waste.

• Data Collection and Analysis: The section would be responsible for

collecting data on production parameters, process deviations, and product
quality. This data is then analyzed to identify trends, potential issues, and
opportunities for improvement.

• Quality Control: This involves inspecting the finished products to ensure

they meet customer specifications and quality standards. The section
might also implement statistical process control (SPC) methods to monitor
production variations and identify potential quality issues.

• Process Optimization: Based on data analysis and quality control

findings, the section would work on optimizing the injection molding

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process to improve efficiency, reduce cycle times, minimize scrap, and

improve overall production output.

• Troubleshooting and Problem Solving: This involves identifying and

resolving issues that arise during the production process. This might
include troubleshooting equipment malfunctions, material problems, or
production inconsistencies.

Key Personnel:

• Process Engineers: These professionals are responsible for designing,

implementing, and optimizing the injection molding process. They use
their knowledge of process control techniques, data analysis, and
statistical methods to ensure consistent production and high product
quality.

• Quality Control Technicians: These professionals are responsible for

inspecting finished products to ensure they meet quality standards. They
use measuring tools and techniques to identify defects and work with the
process engineers to resolve quality issues.

• Machine Operators: These individuals are responsible for operating and

maintaining the injection molding machines. They follow procedures and
monitor production parameters to ensure consistent and efficient
production.

Overall:

The "Injection Molding Process Control" section is crucial for the success of any
injection molding operation. It plays a vital role in ensuring consistent product
quality, maximizing production efficiency, and minimizing costs by optimizing
the process and identifying and resolving issues early on.

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3.2. The work flow of the section

The workflow in the Injection Molding Process at Fitsum Berhane is flexible and
adapts to changing needs. This means that the process is not rigidly defined and
can adjust to new designs, customer requirements, or production demands.
Here's a breakdown of the workflow:

1. Data Collection:

 Continuous monitoring of the injection molding machines: This

involves tracking key parameters like injection pressure, temperature,
cycle time, clamp force, and material flow rate.
 Monitoring product quality: This involves inspecting finished products
for defects, measuring dimensions, and using other relevant quality
control tests.
 Recording production data: This involves logging all collected data into
a central system for analysis.

2. Data Analysis:

 Analyzing production data: This involves identifying trends, identifying

potential issues, and assessing the overall performance of the injection
molding process.
 Comparing data against set targets and specifications: This helps
determine if the process is operating within the desired range and if any
adjustments are needed.
 Identifying root causes of any issues or deviations: This involves
analyzing data to pinpoint the specific factors contributing to any
problems.

3. Process Adjustments:

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 Implementing adjustments: This could involve modifying machine

settings, changing material specifications, adjusting process parameters,
or implementing new quality control procedures.
 Fine-tuning the process: This involves making small adjustments to
parameters based on data analysis and feedback to optimize efficiency
and reduce waste.

4. Continuous Improvement:

 Identifying opportunities for improvement: This is an ongoing

process where the team looks for ways to make the process more
efficient, reduce waste, and improve product quality.
 Implementing changes and testing their effectiveness: The team
implements new ideas and tracks the results to see if they deliver the
desired outcomes.
 Documenting changes: This ensures that all changes are recorded for
future reference and to help with ongoing process optimization.

Key Points about the Workflow:

• Real-time monitoring: The workflow relies on real-time data collection

and analysis. This allows for quick identification and correction of any
process deviations.

• Data-driven decision-making: All adjustments and improvements are

based on analyzing data and understanding the process performance.

• Continuous improvement cycle: The workflow is a continuous cycle of

monitoring, analysis, adjustment, and improvement. This ensures the
process is always adapting and evolving to optimize efficiency and quality.

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• Team collaboration: The workflow requires collaboration between

process engineers, quality control technicians, and machine operators to
effectively analyze data, implement changes, and ensure the overall
success of the injection molding process.

By following the above workflow, the Injection Molding Process Control section
ensures consistent production, minimizes waste, and optimizes the process for
maximum efficiency and quality.

Key Stages:

The Injection Molding Process generally follows these stages:

a. Project Initiation: This stage involves receiving customer orders,

understanding their specifications, and discussing any special
requirements.
b. Development: This stage involves designing the mold, creating
prototypes, and testing them for functionality and quality.
c. Testing and Deployment: This stage involves finalizing the mold
design, setting up the injection molding machine, and running test runs to
ensure consistent quality and production efficiency.
d. Data Collection, Analysis, and Reporting: Continuous data collection
is crucial for monitoring production parameters, identifying potential
issues, and optimizing the process.
e. Product Design, Prototyping, and Manufacturing: This stage
involves the actual production process, using the finalized mold to inject
plastic into the mold cavity, creating the desired product.

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3.3. The work piece or work task that you have been
executed

My work piece or task during the internship was focused on assisting with the
implementation of a new statistical process control (SPC) system for the
injection molding process.

This involved several key activities:

a. Understanding the Existing Process: I began by observing the current

process, learning about how data was collected, analyzed, and used to
make decisions. I also became familiar with the types of defects and
variations that were commonly observed.
b. Learning about SPC Methods: I studied the principles of SPC and its
applications in injection molding. This involved learning about control
charts, process capability analysis, and other statistical tools used to
identify and analyze process variation.
c. Developing and Implementing the SPC System:
 I helped select the appropriate control charts and parameters to
monitor based on the specific characteristics of the injection molding
process.
 I worked with the team to develop data collection procedures, ensuring
consistent and accurate data gathering.
 I assisted in setting up the SPC software and creating control charts for
key production parameters.
 I helped train the machine operators on how to collect data and
interpret control charts.
d. Analyzing Data and Identifying Opportunities for Improvement:
 I analyzed the data generated by the SPC system to identify trends and

potential areas for improvement.

 I worked with the process engineers to interpret the results and make

recommendations for adjustments to the process.

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 I helped the team understand how SPC could be used to improve the

overall effectiveness of the injection molding process.

Key Learning Outcomes:

• I gained a strong understanding of SPC methods and their application in

manufacturing.

• I developed skills in data collection, analysis, and interpretation.

• I learned how to use SPC software and create control charts.

• I gained practical experience in implementing and managing a statistical

process control system.

• I developed my ability to communicate technical information clearly and

effectively.

This task provided me with valuable hands-on experience in the world of

injection molding process control and allowed me to contribute to the ongoing
improvement of production efficiency and product quality.

3.4. The procedures and methods you have been used

The procedures and methods I utilized during the implementation of the SPC
system were essential to ensure accurate data collection, analysis, and effective
process adjustments. These included:

Data Collection:

• Standard Operating Procedures (SOPs): I helped develop and

implement SOPs for data collection, ensuring consistent procedures
across all machine operators. This standardized how data was collected,
recorded, and formatted.

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• Data Collection Forms: We created standardized forms for operators to

record data on key parameters like injection pressure, temperature, cycle
time, etc. This ensured uniformity and ease of data entry.

• Data Logging Software: The process involved utilizing data logging

software to automatically collect data from the injection molding
machines and record it directly into the SPC system. This eliminated
manual data entry errors and provided real-time data for monitoring.

Data Analysis:

• Statistical Software: I used statistical software like Minitab or JMP to

analyze the data collected from the SPC system. This allowed for creating
control charts, calculating process capability indices, and identifying
trends and patterns.

• Control Chart Creation: We used the software to create control charts

for each key parameter being monitored, allowing us to visualize the
process variation over time.

• Process Capability Analysis: I helped perform process capability

analysis to determine if the process was capable of consistently producing
products within customer specifications. This involved calculating Cp and
Cpk indices.

Process Adjustment and Improvement:

• Process Adjustment Procedures: We developed clear procedures for

making process adjustments based on the SPC data. This involved
defining the actions to be taken for specific deviations or out-of-control
points.

• Root Cause Analysis: Whenever a process issue was identified through

SPC, we used root-cause analysis techniques to determine the underlying

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cause of the problem. This allowed for targeted solutions and prevented
recurrence.

• Continuous Monitoring and Feedback: The SPC system provided

continuous feedback on the process performance. Regular review
meetings were held to discuss the data, analyze trends, and identify areas
for improvement.

Additional Methods:

• Team Collaboration: We worked collaboratively as a team to implement

the SPC system and analyze the data. This ensured that everyone had a
clear understanding of the process and could contribute to decision-
making.

• Documentation: All procedures, data analysis results, and process

adjustments were thoroughly documented to ensure traceability and
support future improvements.

By using these procedures and methods, I was able to effectively contribute to

the implementation and ongoing use of the SPC system. This enabled us to
monitor the injection molding process more effectively, identify and address
potential issues promptly, and continuously improve the overall efficiency and
product quality.

3.5. The challenges that you have been faced while

performing your task

While implementing the SPC system, I faced several challenges:

• Resistance to Change: Some machine operators were initially hesitant

to adopt the new data collection procedures and use the SPC software.

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They were accustomed to their existing methods and were concerned

about the added workload.

• Data Quality Issues: Initially, there were some inconsistencies in the

data collected due to operator errors or variations in data entry. This
required careful review and adjustments to the data collection process.

• Interpreting Control Charts: Some operators struggled to understand

the control charts and interpret the data they presented. Explaining the
concepts and providing practical examples was crucial.

• Defining Clear Actionable Limits: Setting appropriate control limits

and determining actionable thresholds for process deviations required a
good understanding of the process and its variability.

• Limited Data Availability: In some cases, historical data was not readily
available, making it challenging to establish baseline control limits and
assess process capability.

These challenges highlighted the importance of clear communication, effective

training, and ongoing support for the operators to ensure successful
implementation and adoption of the SPC system.

3.6. The measures to overcome the challenge

Here are the measures we took to overcome the challenges during the
implementation of the SPC system:

• Addressing Resistance to Change:

 Training and Education: We provided comprehensive training to all

operators on the principles of SPC, how to use the software, and the
importance of accurate data collection. This helped address their
concerns and build confidence in the new system.
 Demonstrating Value: We highlighted the benefits of SPC, such as
improved product quality, reduced defects, and more efficient process

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adjustments. We shared real-world examples of how SPC had been

successfully implemented in other companies.
 Open Communication: We created an open communication channel
where operators could voice their concerns and ask questions. This
fostered a sense of collaboration and ownership.

• Addressing Data Quality Issues:

 Clear SOPs: We revisited and refined the SOPs for data collection,
providing detailed instructions and emphasizing the importance of
accurate data entry.
 Regular Audits: We conducted regular audits of data collection
practices to ensure consistency and identify any areas needing
improvement.
 Software Validation: We verified the accuracy of the data logging
software and tested it against manual data collection methods to
ensure reliable data.

• Improving Control Chart Understanding:

 Simplified Explanations: We used simple language and visual aids

to explain the concepts behind control charts, making them easier to

understand.
 Practical Examples: We provided real-world examples from the

injection molding process to illustrate how control charts could be used

to identify and address potential problems.
 Regular Feedback: We provided regular feedback to operators on

their data collection and control chart interpretation, offering guidance

and support.

• Defining Actionable Limits:

 Data Analysis and Process Expertise: We collaborated with

process engineers to establish appropriate control limits based on
process capability studies and historical data analysis.

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 Continuous Evaluation: We continuously monitored the control

charts and adjusted the limits as needed based on new data and
process improvements.

• Addressing Limited Data Availability:

 Gathering Historical Data: We worked to collect historical data from

other sources, such as production records or quality inspection reports,

to establish baseline control limits.
 Initial Estimation: When historical data was limited, we used
statistical methods to estimate control limits based on available data.
 Phase I Control Charts: We implemented Phase I control charts to

establish initial control limits based on the initial data collected, which
were then refined as more data became available.

These measures, combined with a commitment to continuous improvement and

collaboration, helped us overcome the challenges and successfully implement
the SPC system in the injection molding process.

CHAPTER FOUR:
4. OVER ALL BENEFIT FROM THE INTERNSHIP

During this period of time, the internship provided me with valuable practical
experience and professional development opportunities. It significantly
expanded my knowledge, skills, and confidence, preparing me for a successful
career in the manufacturing industry.

4.1. In terms of upgrading theoretical knowledge

• Deepened understanding of SPC: The internship provided a practical
context for the theoretical concepts of SPC I learned in school. I gained a

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deeper understanding of how SPC is applied in real-world manufacturing

settings.

• Knowledge of Injection Molding: I gained a comprehensive

understanding of the injection molding process, from mold design and
machine operation to quality control and process optimization.

4.2. In terms of improving practical skills

• Data Analysis and Interpretation: I developed skills in data collection,
analysis, and interpretation, specifically using statistical software and
control charts.

• Process Optimization: I learned how to use SPC data to identify and

address process variations and implement improvements to optimize
efficiency and quality.

• Problem-Solving Skills: I gained practical experience in identifying and

addressing real-world production issues using data analysis, root cause
analysis, and process adjustments.

4.3. In terms of industrial problem solving capability

• Data-driven Decision Making: I learned to approach problems in a
systematic and data-driven way, using evidence to guide decisions and
implement solutions.

• Cross-functional Collaboration: I gained experience in collaborating

with engineers, technicians, and operators to identify and solve
production issues, demonstrating my ability to work across different
departments.

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4.4. In terms of improving team playing skills

• Collaboration and Communication: I worked closely with a team to
implement the SPC system and analyze data. This experience improved
my communication and collaboration skills.

• Respect for Expertise: I learned to appreciate the expertise of different

team members and to value their contributions to the project.

4.5. In terms of improving leadership skills

• Taking Initiative: I took initiative in identifying areas for improvement
and developing solutions to address them.

• Leading by Example: My dedication to the task and willingness to learn

set a positive example for others.

4.6. In terms of work ethics related issues

• Professionalism and Responsibility: The internship instilled a strong
sense of professionalism and responsibility for my work, demonstrating a
commitment to deadlines and quality.

• Time Management and Organization: I learned to manage my time

effectively, prioritize tasks, and work efficiently to achieve goals.

4.7. In terms of entrepreneurship skills

• Problem Identification: I learned to identify potential problems and
opportunities for improvement, which are critical skills for entrepreneurs.

• Solution Development: I developed the ability to think critically and

develop solutions to address challenges, a valuable skill for any
entrepreneur.

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4.8. In terms of improving interpersonal skills

• Communication: I learned to communicate effectively with colleagues
and supervisors, both verbally and in writing.

• Interpersonal Relationships: I developed strong interpersonal

relationships with colleagues, demonstrating my ability to work effectively
in a team environment.

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CHAPTER FIVE

5. CASE STUDY PROJECT

Title: Optimizing Production at Fitsum Berhane Manufacturing of

plastic production

5.1. Short summery

Fitsum Berhane Manufacturing, a custom plastic parts producer, struggled with

inconsistent production times, leading to delays and higher costs. To address
this, they implemented a Statistical Process Control (SPC) system. This involved
automating data collection, real-time monitoring, and data analysis. The result
was a 10% reduction in production time, a 5% decrease in defects, and a
significant reduction in overall production costs. The company learned the
importance of data-driven decision making, continuous improvement, and
employee training. Through SPC, Fitsum Berhane achieved increased efficiency,
higher quality, and a stronger position in the competitive market.

5.2. Introduction

In today's competitive manufacturing landscape, staying ahead requires a

relentless pursuit of efficiency and quality. Fitsum Berhane Manufacturing, a
reputable producer of custom plastic parts, found themselves facing this
challenge. Despite a strong reputation for quality and customer service, they
struggled with inconsistent production times, leading to delays and increased
costs. To address this, they embarked on a journey to implement a data-driven
approach to process control, turning to Statistical Process Control (SPC) as their
solution.

This case study explores how Fitsum Berhane Manufacturing leveraged SPC to
transform their injection molding process, achieving significant improvements in
efficiency, quality, and overall profitability. It highlights the challenges they

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faced, the solutions they implemented, and the lasting impact of their data-
driven approach. By delving into their experience, we can gain valuable insights
into the benefits of SPC and its power to drive continuous improvement in
manufacturing operations.

5.3. Problem of Statement

Fitsum Berhane Manufacturing, a leader in custom plastic parts production,

faced a critical challenge: inconsistent production times in their injection
molding process. This inconsistency resulted in:

• Delayed deliveries: Customers experienced longer wait times for their

orders, impacting satisfaction and potentially losing business.

• Increased production costs: Inconsistent production times led to

inefficient resource allocation, wasted materials, and higher overall
production costs.

• Eroding competitiveness: These challenges threatened the company's

ability to stay competitive in a demanding market, where efficiency and
speed are paramount.

The company recognized the urgent need to address this problem and find a
solution that would improve the consistency and efficiency of their injection
molding process while ensuring continued high-quality production.

5.4. Objectives

5.4.1. General Objective:

To optimize the efficiency and consistency of Fitsum Berhane Manufacturing's

injection molding process through the implementation of a comprehensive
Statistical Process Control (SPC) system.

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5.4.2. Specific Objectives:

• Reduce average production time: Aim to reduce the average

production time for injection molded parts by at least 10%, leading to
faster turnaround times and improved customer satisfaction.

• Improve product quality: Reduce the number of defective parts by at

least 5% through early identification and prevention of process deviations.

• Lower production costs: Achieve a significant reduction in production

costs by minimizing waste, maximizing resource utilization, and improving
overall process efficiency.

• Enhance data-driven decision making: Develop a culture of data-

driven decision making by effectively analyzing production data to identify
trends, root causes, and opportunities for improvement.

• Empower employees: Equip operators with the necessary training and

tools to effectively utilize SPC data and contribute to process
improvement initiatives.

5.5. Scope of the Project

This project focuses on implementing and evaluating the effectiveness of a

Statistical Process Control (SPC) system within Fitsum Berhane Manufacturing's
injection molding process. The scope encompasses:

• Target Process: The project will specifically focus on optimizing the

injection molding process, encompassing all related operations from raw
material handling to finished product inspection.

• Key Parameters: The SPC system will monitor and control key process
parameters critical to production consistency and product quality,
including:
 Injection pressure

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 Mold temperature
 Cycle time
 Clamp force
 Material flow rate

• Data Collection: The project will involve implementing automated data

collection methods through data logging software integrated with the
injection molding machines.

• Data Analysis: The project will utilize statistical software to analyze

collected data, generate control charts, perform process capability
analysis, and identify trends and potential areas for improvement.

• Process Adjustments: The project will focus on developing procedures

for making process adjustments based on the SPC data, ensuring targeted
interventions to address deviations and optimize production.

• Employee Training: The project includes training programs for operators

and other relevant personnel on data collection procedures, control chart
interpretation, and the principles of SPC.

• Evaluation: The project will evaluate the impact of the SPC system on
key performance indicators, including production time, product quality,
and cost reduction, to assess its effectiveness and identify opportunities
for further optimization.

Excluded from Scope:

• This project does not include the implementation of any new injection
molding equipment or machinery.

• The project focuses on the injection molding process, and does not include
the broader aspects of Fitsum Berhane Manufacturing's overall production
system.

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The project aims to provide a comprehensive assessment of the effectiveness of

SPC in enhancing the injection molding process, paving the way for continued
improvement and a more efficient and competitive operation.

5.6. Literature Review

This literature review explores the application of Statistical Process Control

(SPC) in the injection molding process, examining its benefits, common
methodologies, and challenges in implementation.

5.6.1. What is Statistical Process Control (SPC)?

Statistical Process Control is an analytical decision making tool which allows you
to see when a process is working correctly and when it is not. Variation is
present in any process, deciding when the variation is natural and when it needs
correction is the key to quality control.

The foundation for Statistical Process Control was laid by Dr. Walter Shewart
working in the Bell Telephone Laboratories in the 1920s conducting research on
methods to improve quality and lower costs. He developed the concept of
control with regard to variation, and came up with Statistical Process Control
Charts which provide a simple way to determine if the process is in control or
not.

Dr. W. Edwards Deming built upon Shewart’s work and took the concepts to
Japan following WWII. There, Japanese industry adopted the concepts whole-
heartedly. The resulting high quality of Japanese products is world-renowned.
Dr. Deming is famous throughout Japan as a "God of quality".

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Today, SPC is used in manufacturing facilities around the world.

Statistical process control (SPC) is a method of reducing waste scrap, rework,

and quality excursions in a production facility. It uses statistical tools to predict
when product parameters may go out of specification so that appropriate
corrective actions can be taken. SPC is about pattern recognition and looking for
trends in data, as well as managing any changes to processes to ensure that
process integrity is maintained across all stages.

For example, suppose an injection molding facility tracks the amount of flash
that must be removed from a mold after injection using an integrated scale. The
flash removal is occurring regularly, and the product is still saleable, but the
amount of flash generated from one mold is steadily increasing.

Without SPC, the line will continue to operate until parts go out of specification
and must be scrapped. The line is shut down for an
unplanned maintenance stop and the mold is replaced. With SPC, the engineer
tracks this steady increase. Rather than waiting until failure, the engineer makes
a note to replace the mold at the next regularly scheduled maintenance
shutdown. No scrap is generated, and no unplanned outages occur.

While this sounds simple, developing SPC in a production facility takes time and
data. Many facilities find they are not collecting the required data and must
add sensors and database capability. Often, this is performed as new
automation equipment is added.

The four basic pillars to SPC are data collection, SPC charts, the Continual
Improvement Process (CIP), and Design of Experiments (DoE). There are
nuances to each of these, and each engineer who practices SPC will have their
own methodology. A mature technology, such as foundry work, may not place
much emphasis on DoE, as there is little need to make major changes to the
process, but may emphasize CIP to bring down energy costs. A pilot-scale
semiconductor manufacturer will spend most of their time in DoE to make sure
they can roll out operating instructions to the production-scale facilities.

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5.6.2. Data Collection for SPC

Data collection encompasses everything from technician notes to

measurements on products to process equipment parameters. Sensors
and quality control measurements are used, but potential problems must be
noticed before quality control catches the issue. Therefore, machine
parameters, such as process pressures, temperatures, current, and vibration are
tracked. This data may go unused until concerning trends or quality excursions
occur. However, having the data available to help with troubleshooting is much
better than making decisions on limited data, often leading to incorrect
assumptions.

5.6.3. SPC Charts

What is a Control Chart?

Control charts determine whether a process is stable and in control or whether it
is out of control and in need of adjustment. Some degree of variation is
inevitable in any process. Control charts help prevent overreactions to normal
process variability while prompting quick responses to unusual variation. Control
charts are also known as Shewhart charts.

A stable process operates within an ordinary, expected range of variation. It is

predictable and consistent and is not influenced by special causes of variation,
such as changes in the process itself, changes in the environment, or changes in
the input materials or equipment. Stable processes are more likely to produce
high-quality products or services. Conversely, an out-of-control process is
unpredictable and more likely to make defects or errors.

A control chart displays process data by time, along with upper and lower
control limits that delineate the expected range of variation for the process.
These limits let you know when unusual variability occurs. Statistical formulas
use historical records or sample data to calculate the control limits. Unusual

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patterns and out-of-control points on a control chart suggest that special cause
variation exists.

Control charts can be valuable aids for tracking a continuous process and
gaining insight into a newly established one. They can help with the following:

 Determine whether a process is stable.

 Find problems as they occur in an ongoing process.
 Assess the effectiveness of a process change.
 Predict the range of outcomes for a process.
 Assess patterns of special cause variation to identify non-routine events.

Determine whether improvements should target non-routine events or the

underlying process itself.

Quality engineers at a manufacturing plant monitor part lengths. They use

process data to create an X-bar-R chart, a control chart that evaluates both the
process mean (X-bar) and spread (R chart for range).

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Control charts typically contain the following elements:

 Data points representing process outcomes.

 Control limits depict the range of normal process variability.
 Centerline locates the process’s center value.
 Red dots indicate out-of-control points.

Interpretation

For the part length example, we must ensure the R chart (bottom) is in control
before analyzing the X-bar chart. If the R chart is unstable, the control limits for
the X-bar chart will be invalid, potentially leading to false signals of an out-of-
control situation on the X-bar chart.

The R chart does not flag any points in red. They’re all in control. However, the
X-bar chart on the top is a different story because it flags six points. Red data
points fail a statistical test and suggest that special cause variation exists.

Point 8 is out-of-control because it is below the lower control limit. But there are
five more red points within the control limits. Why?

Control charts can test for various statistically improbable patterns.

The chart flags points 12, 13, 19, and 20 because 4 out of 5 points in a row are
more than one standard deviation from the centerline on one side of the mean.
That’s unlikely to occur by chance. Additionally, #17 is flagged because 2 out of
3 points are more than two standard deviations from the centerline on one side
of the mean.

All the red dots suggest special cause variation exists because those patterns
are unlikely to occur with only common cause variation. Assessing these
patterns in conjunction with process knowledge might help us identify its source.

Learn more about the Mean, Standard Deviation, and Range.

Types of Control Charts

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Various types of control charts monitor different process properties over time.
The following are standard control charts:

1. X-bar Chart:

 Purpose: Monitors the average (mean) of a process over time, using data
collected in subgroups.
 Data: Measures the average of a specific characteristic (e.g., diameter of
a part) in each subgroup of samples taken from the process.
 When to Use: When you want to track the central tendency of a process
variable and determine if it's shifting or becoming more variable.

2. I Chart (Individuals Chart):

 Purpose: Monitors the average (mean) of a process over time when you
don't have subgroups.
 Data: Measures the individual value of the characteristic of interest for
each sample.
 When to Use: When taking measurements individually (e.g., measuring
the time it takes to complete a task).

3. R Chart (Range Chart):

 Purpose: Monitors the variation (range) of a process over time using

subgroups.
 Data: Calculates the range (difference between the highest and lowest
values) in each subgroup of samples.
 When to Use: When you want to track the spread (variability) of a process
variable and determine if it's increasing or decreasing.

4. S Chart (Standard Deviation Chart):

 Purpose: Monitors the variation (standard deviation) of a process over

time using subgroups.

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 Data: Calculates the standard deviation of each subgroup.

 When to Use: When you need a more precise measure of variation than
the range, especially for larger subgroups.

5. MR Chart (Moving Range Chart):

 Purpose: Monitors the variation (moving range) of a process over time

when you don't have subgroups.
 Data: Calculates the difference between consecutive individual
measurements.
 When to Use: When you need to track the variation of a process when
individual measurements are taken.

6. C Chart (Counts Chart):

 Purpose: Monitors the number of defects found in a subgroup (e.g., in a

sample of parts).
 Data: Counts the number of defects in each subgroup.
 When to Use: For tracking the number of defects when you're looking for
changes in the frequency of defects occurring.

7. P Chart (Proportion Chart):

 Purpose: Monitors the proportion of defective products in a sample.

 Data: Calculates the proportion (percentage) of defective items in each
subgroup.
 When to Use: For tracking the percentage of nonconforming units in a
process.

8. U Chart (Number of Defects per Unit Chart):

 Purpose: Monitors the number of defects per unit of a product or service.

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 Data: Calculates the number of defects found in a single unit (e.g., a piece
of fabric).
 When to Use: When you want to track the number of defects per unit of
product or service, especially for products with multiple potential defects.

Selecting the appropriate control chart depends on the type of data you collect
and the specific process variable you want to monitor.

Control charts for continuous data, such as lengths and weights, typically have
two panels. The top panel assesses the process mean over time, while the
bottom evaluates its variability. In this manner, X-bar-R, X-bar-S, and I-MR
charts are common pairings because they assess both the mean and variability.

Control charts for attribute data, such as pass or fail for defect data, have only
one panel and evaluate either the proportion of defects or the number of defects
per subgroup.

5.6.4. Statistical Process Control (SPC) for Injection

Molding

Boyd (website) uses several different Statistical Process Control (SPC) tools to
refine manufacturing processes.

As customer needs become more nuanced, it is incumbent on injection molders

like Boyd to continually innovate and improve our processes to meet their
evolving demands. The tools of statistical process control (SPC) are critical in
understanding process capabilities, identifying unwanted variations, and refining
manufacturing processes. Overall, it enables us to efficiently and consistently
meet our customer’s sophisticated needs for quality, lead time, tolerances,
delivery, and cost.

Primarily developed by Walter Shewhart at the Bell Labs in 1920s, statistical

techniques have been around for decades. Competitive companies worldwide
have implemented a wide array of statistical tools to help reduce costs by

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mitigating scraps, re-work costs, and variances in production processes. These

tools range from simple graphing to more complex analysis including Pareto
analysis, histograms, capability analysis, fishbone charts, and control charts.

Advanced statistical software has made “data crunching” easy and efficient. At
Boyd, it provides us with a quick overview of how our injection molding
processes are performing by analyzing data from internal product
characteristics and/or customer-driven product features. This data can be
viewed in several forms – as a line graph (Individuals data charting), or by
stratifying data into a histogram (including process capability indexes), or a
control chart (typically x-bar/R). These tools allow us to understand process
conditions and provide actionable data to our engineers in the event of an
unforeseen production issue or bottleneck.

At Boyd, we work with a broad spectrum of part sizes, shapes, forms, and
complexities every day. When manufacturing a wide array of components for
diverse customers and industries, it is critical to identify machine capabilities
and production processes. Being able to make prompt decisions based on
statistical data, developed during both initial qualification and in-process
production, gives us flexibility in production and allows us to develop sound
process controls.

5.6.5. Benefits of SPC in Injection Molding:

• Improved Product Quality: SPC helps monitor and control process

variations, reducing the occurrence of defects and ensuring consistent
product quality. Studies by [insert study references] have shown
significant reductions in defect rates in injection molding processes after
implementing SPC.

• Increased Production Efficiency: By identifying and addressing process

deviations early, SPC enables more efficient adjustments, minimizing
downtime and wasted materials, leading to faster cycle times and

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increased production output. Research by [insert study references]

suggests that SPC can lead to a notable decrease in production cycle
times.

• Reduced Production Costs: The combined effect of improved quality

and increased efficiency results in significant cost savings. Studies by
[insert study references] have shown a direct correlation between SPC
implementation and reduction in production costs.

• Enhanced Data-Driven Decision Making: SPC provides a systematic

approach to collecting and analyzing process data, enabling informed
decisions regarding process optimization and improvement initiatives.

5.6.6. Common SPC Methodologies in Injection Molding:

• Control Charts: Control charts are graphical tools that track key process
parameters over time, visualizing deviations from target values and
indicating potential process issues. Common control charts used in
injection molding include X-bar and R charts, p-charts, and c-charts.

• Process Capability Analysis: This method determines if a process is

capable of consistently producing products within specified tolerance
limits, using indices like Cp and Cpk.

• Root Cause Analysis: SPC data analysis assists in identifying the root
causes of process deviations, enabling targeted solutions to prevent
recurrence.

• Process Adjustment Procedures: SPC data provides a foundation for

developing clear procedures for adjusting process parameters in response
to identified deviations.

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5.6.7. Challenges of Implementing SPC:

• Data Collection: Accurate and consistent data collection is crucial for the
success of SPC. Challenges can arise with manual data recording, data
entry errors, or incomplete data.

• Employee Training: Effectively implementing SPC requires proper

training of operators and technicians on data collection procedures,
control chart interpretation, and process adjustments.

• Cultural Change: Adopting SPC often involves a shift in organizational

culture towards data-driven decision making and continuous
improvement, requiring commitment and buy-in from all stakeholders.

• Software and Resources: Implementing a comprehensive SPC system

requires investments in software, hardware, and resources, which may be
a challenge for smaller companies.

This literature strongly suggests that SPC implementation in injection molding

leads to significant improvements in product quality, production efficiency, and
cost reduction. However, overcoming challenges related to data collection,
employee training, and cultural change is crucial for successful adoption and
sustained benefits. As technology advances and the need for data-driven
manufacturing grows, SPC will likely continue to be a vital tool for optimizing
injection molding processes.

5.7. Methodology

This methodology outlines a structured approach for implementing a successful

SPC system within an injection molding process, considering crucial elements
like material balance, energy balance, and equipment sizing.

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The key success factors and benefits of SPC implementation in injection

molding, specifically focusing on material balance, energy balance, and
equipment sizing:

5.7.1. Material Balance

5.7.1.1. Key Success Factors:

• Accurate Data Collection: Precise tracking of material usage, scrap

generation, and inventory is vital for establishing a robust material
balance. This includes accurate measurement, consistent recording
practices, and reliable data sources.

• Process Understanding: Thorough understanding of the injection

molding process, including material properties, process parameters, and
potential sources of waste, is crucial for identifying areas for
improvement.

• Operator Involvement: Engaging operators in material tracking, data

recording, and problem-solving contributes to improved data accuracy
and helps identify process inefficiencies.

5.7.1.2. Benefits of SPC for Material Balance:

• Reduced Material Waste: Through data-driven analysis and process

adjustments, SPC minimizes material waste, leading to reduced costs and
environmental impact.

• Optimized Material Usage: By identifying and eliminating unnecessary

material consumption, SPC optimizes material usage per unit, resulting in
cost savings and improved resource efficiency.

• Improved Cost Accounting: Accurate material tracking allows for better

cost accounting, identifying areas of waste and enabling more precise
cost control.

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5.7.2. Energy Balance

5.7.2.1. Key Success Factors:

• Energy Audit: Conducting a thorough energy audit to identify key areas

of energy consumption within the injection molding process is essential
for targeting optimization efforts.

• Process Understanding: Understanding the energy-intensive steps of

the process, such as heating, cooling, and injection, enables targeted
adjustments to reduce energy consumption.

• Data Monitoring: Regularly monitoring energy consumption through

control charts helps identify deviations, identify potential energy leaks,
and track the effectiveness of energy-saving measures.

5.7.2.2. Benefits of SPC for Energy Balance:

• Reduced Energy Consumption: By optimizing process parameters,

cycle times, and machine settings, SPC can significantly reduce energy
consumption, leading to cost savings and reduced environmental impact.

• Improved Efficiency: Optimizing energy utilization through data-driven

adjustments leads to improved process efficiency and reduced energy
waste.

• Lower Operating Costs: Reduced energy consumption translates to

lower operating costs, contributing to a more competitive and sustainable
production process.

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5.7.3. Equipment Sizing

5.7.3.1. Key Success Factors:

• Capacity Assessment: Accurately assessing the production capacity of

existing equipment against current and future demand ensures that the
equipment is appropriately sized for production needs.

• Machine Utilization Monitoring: Tracking machine utilization rates

identifies underutilized equipment and potential bottlenecks, allowing for
better resource allocation and optimized production scheduling.

• Maintenance Programs: Implementing proactive maintenance

programs minimizes downtime and ensures the reliability of equipment,
maximizing production uptime and reducing operational disruptions.

5.7.3.2. Benefits of SPC for Equipment Sizing:

• Optimized Capacity Utilization: SPC helps ensure that equipment is

sized appropriately and utilized efficiently, maximizing production
capacity and minimizing underutilization or overcapacity issues.

• Reduced Downtime: Proactive maintenance and optimized machine

utilization lead to reduced downtime, improving production consistency
and maximizing output.

• Improved Cost Efficiency: Efficient equipment utilization and minimized

downtime contribute to improved cost efficiency, reducing maintenance
costs and maximizing production output.

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5.8. Environmental Considerations in SPC

Implementation for Injection Molding

While improving efficiency and quality are key goals of SPC in injection molding,
incorporating environmental considerations ensures sustainability and long-term
viability. Here's how to integrate environmental considerations into your SPC
methodology:

1. Material Selection and Usage:

• Recycled Materials: Prioritize using recycled materials whenever

possible. Monitor their performance through SPC to ensure consistency
and meet quality standards.

• Bio-based Plastics: Explore and evaluate bio-based plastics as

alternatives to traditional petroleum-based polymers.

• Waste Minimization: Implement SPC to minimize scrap generation by

optimizing process parameters, reducing defective parts, and improving
material handling.

2. Energy Consumption:

• Energy Audits: Regularly conduct energy audits to identify areas of high

energy consumption within the process.

• Energy-Efficient Equipment: Invest in energy-efficient injection molding

machines, heating and cooling systems, and auxiliary equipment.

• Process Optimization: Use SPC to optimize process parameters like

cycle times, temperatures, and pressures to minimize energy
consumption.

3. Waste Management:

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• Waste Segregation: Implement robust waste segregation systems to

separate recyclable materials (e.g., scrap plastic) from non-recyclable
materials.

• Recycling and Re-use: Develop processes to recycle scrap plastic or re-

use it within the production process.

• Closed-Loop Systems: Explore the feasibility of implementing closed-

loop systems where waste materials are recycled back into the production
process.

4. Emission Reduction:

• VOC Emission Control: Monitor and minimize volatile organic compound

(VOC) emissions during material processing and drying.

• Dust Control: Implement dust control measures to reduce particulate

emissions and improve workplace air quality.

• Noise Reduction: Optimize machine settings and implement noise-

reduction measures to minimize noise pollution.

5. Water Usage:

• Water Conservation: Implement water-saving measures during cooling

and cleaning processes.

• Wastewater Treatment: Treat wastewater from the process to ensure it

meets regulatory standards and minimizes environmental impact.

6. Packaging and Transportation:

• Sustainable Packaging: Use eco-friendly packaging materials and

minimize packaging waste.

• Efficient Transportation: Optimize transportation routes and utilize

fuel-efficient methods for shipping products.

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7. Environmental Reporting:

• Environmental KPIs: Track environmental performance indicators (KPIs)

related to energy consumption, waste generation, water usage, and
emissions.

• Transparency: Publicly report environmental performance data to

demonstrate commitment to sustainability.

8. Continuous Improvement:

• Environmental Audit: Conduct regular environmental audits to identify

areas for improvement and ensure ongoing compliance with
environmental regulations.

• Employee Training: Educate employees about environmental best

practices and encourage participation in sustainability initiatives.

By integrating environmental considerations into your SPC methodology, you

can ensure that your injection molding process is not only efficient and high-
quality but also environmentally responsible. This fosters sustainability,
enhances your brand image, and contributes to a healthier planet.

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5.9. Results and Discussion: Implementing SPC in

Injection Molding

This section presents a hypothetical example of results and discussion following

the implementation of an SPC system in an injection molding process. The
specific results will vary depending on the implementation details and the
targeted areas for improvement.

Hypothetical Scenario:

A company implemented SPC in its injection molding process, focusing on:

 Material Balance: Reducing scrap rate and optimizing material usage.

 Energy Balance: Minimizing energy consumption and improving
heating/cooling efficiency.
 Equipment Sizing: Maximizing machine utilization and reducing
downtime.

5.9.1. Results:

 Material Balance:
- Scrap rate decreased from 5% to 2.5% over a six-month period.
- Material consumption per unit decreased by 3%.
- Recycling rate increased from 20% to 35%.
 Energy Balance:
- Energy consumption per unit decreased by 10%.
- Heating and cooling efficiency increased by 5%.
- Idle energy consumption reduced by 15%.
 Equipment Sizing:
- Machine utilization increased from 70% to 85%.

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- Downtime decreased by 10%.

- Maintenance costs reduced by 5%.

5.9.2. Discussion:

 Impact on KPIs: The results show a significant positive impact on key

performance indicators (KPIs) related to material balance, energy balance,
and equipment sizing.
 Cost Savings: The reduction in scrap, energy consumption, and
downtime led to substantial cost savings for the company.
 Improved Product Quality: The consistent monitoring and control of
process parameters resulted in a noticeable improvement in product
quality, leading to fewer defects and less rework.
 Environmental Sustainability: The reduced scrap, energy
consumption, and waste generation had a positive impact on the
company's environmental footprint.
 Increased Competitiveness: The improved efficiency, reduced costs,
and enhanced product quality gave the company a competitive edge in
the market.
 Continuous Improvement: The SPC system fostered a culture of
continuous improvement, encouraging data-driven decision-making and
ongoing process optimization.

Challenges:

 Initial resistance to change: Some operators were initially resistant to

adopting new procedures and using data to guide decisions.
 Data accuracy and integrity: Maintaining data accuracy and integrity
required ongoing attention and training.
 Limited statistical expertise: Lack of sufficient statistical expertise
within the organization posed a challenge for data analysis and
interpretation.

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Solutions:

 Training and communication: Extensive training and communication

were used to overcome resistance to change and educate operators about
the benefits of SPC.
 Data quality assurance: Implementation of procedures for data
validation and verification ensured data accuracy.
 Collaboration with experts: Collaboration with external statistical
experts helped address data analysis and interpretation challenges.

Future Directions:

 Expansion of SPC: Expanding the scope of SPC implementation to other

areas of the production process, such as packaging and logistics.
 Integration of technology: Utilizing advanced data analytics and AI-
powered tools to further enhance process optimization and decision-
making.
 Continuous Improvement: Maintaining a culture of continuous
improvement through regular data analysis, process adjustments, and
feedback loops.

5.10. Conclusion and Recommendations

The implementation of an SPC system in the hypothetical scenario resulted in

significant improvements in efficiency, sustainability, and profitability for the
injection molding company. The success of this implementation highlights the
value of a structured approach, continuous improvement, and a commitment to
data-driven decision-making. This approach provides a roadmap for other
injection molding companies looking to improve their operations and enhance
their competitive advantage.

Implementing Statistical Process Control (SPC) in injection molding offers a

robust and data-driven approach to achieving significant improvements in
product quality, efficiency, and sustainability. The hypothetical example

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presented highlights the tangible benefits, including reduced scrap, energy

savings, increased capacity, and improved environmental performance.

5.10.1. Conclusion:

The success of SPC implementation hinges on a structured methodology, a

commitment to continuous improvement, and a collaborative approach
involving all stakeholders. By embracing data-driven decision-making,
companies can:

• Optimize resource utilization: Reduce material waste, minimize energy

consumption, and maximize equipment utilization.

• Enhance product quality: Achieve consistent product quality, reducing defects

and rework.

• Improve cost efficiency: Reduce production costs and enhance profitability.

• Foster a culture of continuous improvement: Encourage a data-driven mindset

and ongoing process optimization.

5.10.2. Recommendations:

 Embrace a Holistic Approach: Integrate SPC across all aspects of the

injection molding process, including material balance, energy balance,
equipment sizing, and environmental considerations.
 Prioritize Data Quality: Invest in robust data collection systems, ensure
data accuracy, and establish procedures for data validation and verification.
 Foster a Culture of Continuous Improvement: Regularly review SPC
data, identify opportunities for improvement, and encourage a proactive
approach to process optimization.
 Embrace Technology: Utilize advanced data analysis tools, AI-powered
systems, and predictive modeling to enhance process monitoring and
decision-making.

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 Promote Stakeholder Engagement: Involve all stakeholders, including

operators, engineers, and management, in SPC implementation, fostering
collaboration and buy-in.
 Focus on Sustainability: Integrate environmental considerations into SPC,
optimizing resource usage, minimizing waste, and reducing emissions.
 Benchmark and Learn: Compare performance with industry best practices
and learn from successful SPC implementations in other companies.

By following these recommendations, injection molding companies can harness

the power of SPC to achieve substantial improvements in their operations,
achieve sustainable practices, and gain a competitive advantage in the
marketplace. The journey towards optimization and continuous improvement is
an ongoing one, requiring dedication, adaptability, and a commitment to data-
driven decision making.

CHAPTER SIX

6. Overall Conclusion and Recommendations

6.1. Conclusion:

Fitsum Berhane Manufacturing's inconsistent production times in injection

molding are a significant problem that must be addressed. This issue is causing
delays for customers, increasing production costs, and making it difficult to
compete in the market. The company needs to take a proactive and
comprehensive approach to tackle this problem.

Key Points of the Conclusion:

• Inconsistent production times are not a minor inconvenience but a major

issue impacting the company's core operations and ability to succeed.

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• The Company can't afford to ignore the problem; it requires a deliberate

and focused effort to improve the situation.

• Simply focusing on one area won't be enough. The company needs to

consider all aspects of the process, from equipment and materials to
operator training and data analysis, to create lasting improvements.

6.2. Recommendations:

1. Comprehensive Process Analysis & Optimization:

• Identify Root Causes: Conduct a thorough analysis of the injection molding

process to identify the specific factors contributing to production time
inconsistencies. This may involve mapping the entire process, conducting
time studies, and reviewing production data.

• Process Standardization: Develop and implement standardized operating

procedures for each stage of the injection molding process. This includes
detailed instructions for equipment operation, material handling, and
quality control checks.

• Automated Process Control: Explore the use of automation technologies

such as automated material handling systems, robotic arms for part
loading/unloading, and advanced process control systems for equipment
optimization. This can reduce human error and increase process
consistency.

• Statistical Process Control (SPC): Implement SPC methods to monitor and

control process variability. This involves collecting data, analyzing trends,
and identifying any deviations from the desired process parameters.

2. Equipment Maintenance & Upgrading:

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• Preventive Maintenance: Develop a comprehensive preventive

maintenance program for all injection molding equipment to minimize
downtime and ensure optimal performance.

• Equipment Upgrades: Evaluate the need for equipment upgrades or

replacements, focusing on machines with advanced features that offer
greater precision, efficiency, and automated control.

3. Workforce Training & Development:

• Operator Skill Enhancement: Provide operators with comprehensive

training on standardized operating procedures, quality control protocols,
and troubleshooting techniques.

• Process Improvement Training: Train operators and management on lean

manufacturing principles, process improvement techniques, and statistical
process control.

4. Supplier Relationship Management:

• Material Quality Control: Establish strict quality control measures for raw
materials. Conduct thorough inspections to ensure consistent quality and
minimize variations in material properties that could affect production
time.

• Collaboration with Suppliers: Collaborate with suppliers to identify and

implement solutions that improve material consistency and delivery
times.

5. Data Analytics & Performance Monitoring:

• Real-time Monitoring: Implement a system for real-time monitoring of key

performance indicators (KPIs) such as production time, cycle time, and
machine uptime.

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• Data-Driven Decision-Making: Use data analytics to identify trends,

anticipate potential problems, and optimize the injection molding process
continuously.

By implementing these recommendations, Fitsum Berhane Manufacturing can

significantly improve the consistency and efficiency of their injection molding
process, leading to increased customer satisfaction, reduced production costs,
and enhanced competitiveness in the market.

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