Case Study 3

Defroster Nozzle

Activity: Injection Molding

Project Title: Results of 2 Door panels and 1 Bin Assembly & 1 Defroster nozzle

Company: XXXXXX State Indiana

Consultants: Michael Zalipski

Date: August 2001 – December 2001

Client Contact: XXXX

Summary: Evidence of success – Consulting and Training – improving Injection Molding

Process on Chrysler door panels.

Mold 300C

Reduced scrap from 15% to 3%             $114,345.64

Reduced part weight 148 grams

Reduced cycle time 7 seconds

Improved part quality by running on Cavity Pressure Control

Implemented (APC) Automated Part Containment

Reallocated 1 operator per shift – 3 shifts

Mold 307C

Reduced scrap from 8% to 1%               $145,994.40

Reduced part weight 250 grams

Reduced cycle time 6 seconds

Improved part quality by running on Cavity Pressure Control

Implemented (APC) Automated Part Containment

Reallocated 1 operator per shift – 3 shifts

Mold 3530

Reduced scrap from 10% to 5%              $212,544.43

Reduced part weight 28.6 grams

Reduced cycle time 8.9 seconds

Improved part quality by running on Cavity Pressure Control

Implemented (APC) Automated Part Containment

Overall Cost Savings for 3 tools:                    $472,884.43

Total Savings for the 4 Jobs                           $719,531.50