Implementation of a timer system for monitoring raw material pre-heating time in hopper dryers to enhance process accuracy and efficiency in injection moulding

PROBLEM STATEMENT

Pre-heating raw materials in hopper dryers lacked a proper monitoring system, leading to inefficiencies in heating and potential inconsistencies in material quality.

PROBLEM ANALYSIS

Without a timer, operators relied on manual observation or estimates to determine pre-heating duration. This led to variability in heating times, which affected the quality and reliability of the injection moulding process.

ROOT CAUSE

Absence of a standardized timing mechanism for pre-heating raw materials in hopper dryers, resulting in operational inefficiencies and potential errors.

KAIZEN IDEA

Introduce a timer system to the hopper dryers, allowing precise monitoring and control of pre-heating durations for raw materials.

COUNTER MEASURE

Install timers on hopper dryers to monitor and regulate pre-heating times.
Ensure timers are user-friendly and integrated with the existing equipment.
Train operators to use the timer system effectively, emphasizing its role in improving material consistency and process efficiency.

BENCH MARK

Maintain consistent pre-heating times with minimal deviation (e.g., ± 2 minutes).
Reduce material reject rate due to improper pre-heating by 20% or more.
Ensure 100% compliance with pre-heating standards across all operators.

QUANTITATIVE

Enhanced process control: Operators can monitor and manage pre-heating durations more effectively.
Improved material quality: Consistent pre-heating times result in better raw material properties.
Increased operational efficiency: Reduced variability in the process leads to smoother