Last updated on 2024年4月24日

How do you design and use a measurement plan for injection molded parts validation?

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Injection molding is a popular and versatile manufacturing process that can produce complex and precise parts from various materials. However, to ensure that the injection molded parts meet the design specifications and quality standards, you need to validate them with a measurement plan. A measurement plan is a document that defines what, how, and when to measure the critical dimensions and features of the parts, as well as the acceptance criteria and the reporting methods. In this article, you will learn how to design and use a measurement plan for injection molded parts validation.

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Manoj Thakur

Packaging Professional | PMP?| NPD | Procurement | Sustainability | Six Sigma Green Belt | 15+ Years Exp |
Andres Estrada

NetSuite Specialist | Leading Continuous Improvement Initiatives | WMS Implementation Expert
David Moir

Technical Manager (Sales) @ Star Rapid | Specialising in Rapid Injection Molding & Tooling | Bridging Sales…

1 Define the measurement objectives

The first step in designing a measurement plan is to define the measurement objectives. What are the goals and requirements of the validation process? What are the key characteristics and tolerances of the parts that need to be verified? What are the potential sources of variation and error in the injection molding process and the measurement system? By answering these questions, you can establish the scope, purpose, and criteria of the measurement plan.

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Manoj Thakur

Packaging Professional | PMP?| NPD | Procurement | Sustainability | Six Sigma Green Belt | 15+ Years Exp |
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Designing a measurement plan for injection molded parts involves defining critical dimensions, selecting appropriate measurement methods, and establishing tolerance limits. Integral to this plan is the calculation of CP and CPK values, which assess process capability. Target CPK values indicate process capability, typically aiming for 1.33 or higher. Execution includes developing sampling strategies, creating detailed measurement instructions, and calibrating equipment. Continuous monitoring of CPK values allows for process stability assessment and adjustment of parameters as needed. Documentation of results and continuous improvement efforts ensure optimized process performance and part quality.

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Andres Estrada

NetSuite Specialist | Leading Continuous Improvement Initiatives | WMS Implementation Expert
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The role of data management and analysis cannot be overstated; leveraging advanced statistical tools for real-time data analysis fosters proactive decision-making. Also, fostering a culture of continuous learning and improvement among personnel encourages adaptability and innovation in measurement practices, ensuring the long-term success of validation efforts in the dynamic field of injection molding.

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David Moir

Technical Manager (Sales) @ Star Rapid | Specialising in Rapid Injection Molding & Tooling | Bridging Sales, Engineering & Manufacturing | Driving Excellence Within Our Factory
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Go beyond the customer drawing. Alot of dimensions may not be practical to measure outside of a QC lab or without using specialised equipment such as CMM. Internally, you can select your own control dimensions, ones that are very simple to measure at the machine. These might involve simple GO/NO-GO guages, a micrometer or even a set of scales to monitor part weight. If these control dimensions go out of spec, then you can be sure that dimensions the customer cares about, are also out of spec. Determining this at the machine, in process, will reduce number of scrap or quarantined parts and speed up corrective actions.

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2 Select the measurement methods and tools

The next step is to select the measurement methods and tools that are suitable for the measurement objectives. There are different types of measurement methods, such as direct, indirect, destructive, non-destructive, contact, non-contact, manual, automated, and so on. You need to consider the accuracy, precision, repeatability, reproducibility, ease of use, cost, and availability of the measurement methods and tools. Some common measurement tools for injection molded parts are calipers, micrometers, gauges, optical comparators, coordinate measuring machines (CMMs), and vision systems.

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3 Develop the measurement procedure and instructions

The third step is to develop the measurement procedure and instructions that describe how to perform the measurement tasks. The measurement procedure and instructions should include the following elements: the identification and description of the parts and features to be measured, the measurement methods and tools to be used, the calibration and verification of the measurement system, the sampling plan and frequency, the measurement sequence and steps, the data collection and recording format, the calculation and analysis of the measurement results, and the reporting and documentation of the measurement outcomes.

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4 Train and qualify the measurement personnel

The fourth step is to train and qualify the measurement personnel who will execute the measurement plan. The measurement personnel should have the necessary skills, knowledge, and experience to operate the measurement methods and tools, follow the measurement procedure and instructions, interpret the measurement results, and report and document the measurement findings. The measurement personnel should also be familiar with the injection molding process and the part specifications and quality standards. You can use various methods to train and qualify the measurement personnel, such as lectures, demonstrations, simulations, tests, audits, and feedback.

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David Moir

Technical Manager (Sales) @ Star Rapid | Specialising in Rapid Injection Molding & Tooling | Bridging Sales, Engineering & Manufacturing | Driving Excellence Within Our Factory
(已编辑)
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Often, it is easier to train Injection Molding Technicians and operators how to inspect simple, control dimensions at the machine. Rather than try and find QC personel that are also familiar enough with the IM process to be effective. Likewise training QC to become familiar enough to be effective is difficult. Empower operators through training on project specific QC requirements.

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5 Conduct the measurement validation

The fifth step is to conduct the measurement validation according to the measurement plan. The measurement validation is the process of measuring the injection molded parts and comparing the measurement results with the design specifications and quality standards. The measurement validation can be performed at different stages of the injection molding process, such as during the mold design, mold trial, production run, or final inspection. The measurement validation can help you identify and correct any defects, deviations, or variations in the injection molded parts, as well as evaluate and improve the injection molding process and the measurement system.

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6 Review and update the measurement plan

The final step is to review and update the measurement plan based on the measurement validation results and feedback. The measurement plan is not a static document, but a dynamic and iterative one that should be revised and refined as needed. You should review and update the measurement plan to reflect any changes in the injection molding process, the part specifications, the quality standards, the measurement objectives, the measurement methods and tools, the measurement procedure and instructions, or the measurement personnel. You should also monitor and measure the effectiveness and efficiency of the measurement plan and seek opportunities for continuous improvement.

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7 Here’s what else to consider

This is a space to share examples, stories, or insights that don’t fit into any of the previous sections. What else would you like to add?

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Andres Estrada

NetSuite Specialist | Leading Continuous Improvement Initiatives | WMS Implementation Expert
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Beyond the structured steps of designing and using a measurement plan for injection molded parts validation, several critical considerations can enhance the effectiveness and comprehensiveness of the process. It's essential to integrate environmental conditions monitoring, such as temperature and humidity, which can significantly impact measurement accuracy and part dimensions. Engaging in regular audits of measurement processes and tools ensures ongoing compliance and alignment with industry standards and best practices. Additionally, understanding the material properties and behavior under different processing conditions can further refine measurement strategies, accommodating for material-specific variations.

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How do you design and use a measurement plan for injection molded parts validation?

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1 Define the measurement objectives

2 Select the measurement methods and tools

3 Develop the measurement procedure and instructions

4 Train and qualify the measurement personnel

5 Conduct the measurement validation

6 Review and update the measurement plan

7 Here’s what else to consider

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