RJG Newsletter - April 2009

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Process Match and Troubleshooting Workshop
RJG has developed a customized Process Match and Troubleshooting Workshop. This event shows how to develop robust documentation and match processes based on plastic variables. The class also reinforces the importance of thinking "plastic variables" when troubleshooting a process. Attendees will document an existing process and rotate teams where each team will have to match the process based on plastic variables. Once teams are able to match the processes each team will take turns in a stump-the-chump troubleshooting challenge. If labor is available the molds can be moved to another qualified machine where students will learn to think only "plastic variables" when matching a process for the final challenge. Approximately 50% of the time is spent on-machine. For more information contact the Training department at training@rjginc.com.

Save time and money with RJG's eClassroom
Looking to learn without the hassle of travel? Want to gain expertise without costly time away from work? Consider RJG's eClassroom series designed specifically for injection molding professionals. The eClassroom series consists of comprehensive versions of RJG’s renowned scientific molding training courses delivered directly to you via WebEx. Our injection molding experts provide real-time instruction for 1-2 hours per day over a two-week period with review testing. You can “raise your virtual hand” to ask questions, see demonstrations, and re-watch the presentation later. For a complete course schedule and registration/cost details, click here.

Tool Transfer Seminar
With today's economy it's essential that tool transfers be as efficient as possible, so that transferred molds are running quality parts as quickly as possible to maintain profitability. The Tool Transfer Seminar focuses on helping companies deal with the very expensive and time/resource consuming task of transferring a tool. An assessment of the risk factors involved with tool transfers will be discussed as well as ways to leverage the risk to insure success. This class will provide solutions for both users and non-users of cavity pressure technology. Contact the training department for more information.

New Strategies for Lean Injection Molding
Location: Pewaukee, WI

This free seminar focuses on systematic processing strategies and advanced processing technologies that will allow you to consistently manufacture the highest quality parts.

Molders are finding that three key components provide positive results: cavity pressure sensors, process control systems and employee training. Individually each of these components have a positive effect on part quality; when combined the results can be staggering.

This seminar is a must for anyone responsible for the development and manufacturing of plastic parts, or directly involved in part quality issues.

Click here for more information.

Can't afford the time to train?
Interested in on-site, customized training but can’t pull people off the floor for more than 1 day? RJG can schedule 3 companies in a region for one day per company/per week over a period of consecutive weeks. Trainer travel expenses are shared each week. Contact training@rjginc.com if interested in sharing training weeks with other companies in your region.

Help for people out of a job
Grants and Financial Aid Available

If you know someone who is currently out of work due to these hard economic times please let them know that financial aid and grants are available in many states. These grants can help them with technical training such as the RJG Master Molder Modules. In Michigan, for instance, there is the No Worker Left Behind program. Colleges/Universities and Family Independence Agencies may also be good sources for information about these beneficial programs. The RJG training coordinators have contact information in many states for people or agencies that can help get you started. For information please contact the RJG Training Department at 231.933.8175 or email us at training@rjginc.com

RJG Regional Public Training
Upcoming locations are:

DECOUPLED MOLDING SM Process Optimization for Injection Molders
May 5-7, Lombard, IL
May 12-14, 2009 Pewaukee, WI

Systematic Molding I (click here for details):
May 5-7, 2009 Charlotte, NC
June 9-11, 2009 Ogden, UT
May 19-21, 2009 Cocoa Beach, FL
For this class contact Kip Doyle (269) 979-5616

Combination Systematic Molding I - Workshop
May 12-15, 2009 Kerrville, TX
June 2-5, 2009 Apodaca Nuezo Leon, Mexico - NEW!

Master Molder I:
April 27-May 8, 2009 Canton, GA

Please contact training@rjginc.com for more details or call
231-947-3111x 175.
For a list of all upcoming available classes see the RJG Training Schedule.

More Info Links...
RJG Training Schedule
Contact the RJG Training Department
RJG Articles Online

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How stable are the processes running in your plant?

Can you tell if you’re running the right set-ups across your plant at a moments notice?  What about an hour ago?  Last night?

Frustrated from shipping bad parts because
you weren’t running the right job setup? 

RJG's Process Stability Dashboard

RJG has assembled a suite of tools to manage set-ups for all molds that run in your plant whether they have in-cavity sensors or not. Over time our customers have helped us understand that processes are often not set up properly as documented or they get changed after setup. If you have molds without cavity pressure monitoring you may not be able to see these changes occurring and the consequent effect on quality.

When we are able to share with customers what our experience is that 'people' are often a larger process variable than 'material' the response is usually a groan and a rolling of the eyes that lets us know this fact strikes a nerve.

Since you cannot find or manage these variables by walking around the plant an overview is provided on the eDART™ network that shows each machine's status and how much it has deviated from the process it should be running. Once you record a proper process "template" the eDART sends a record of any deviations in machine speeds and pressures from that template to the overview. A quick scan down the overview screen will let you know any processes that are not being run as they should be. Click here for more info or to view a link to an Advanced System Overview Summary video click here.

Solutions for Medical Molders

Process Monitoring & Control for
Medical Molders Webinar

Hosted by Injection Molding Magazine
April 29, 2009 at 2pm
In this webinar we will discuss proven, data driven strategies to simplify validation processes while improving quality and reducing costs. Simple techniques will be presented for documenting processes to allow easy transfer of molds between presses. We will show you the importance of process monitoring, and how to choose the right data to monitor. We will also identify a systematic approach to risk assessment for new molds and examine how to train your processors in scientific molding techniques. Click here to register for this free webinar.

Medical Molding Symposium
May 12, 2009 in Ogden, UT
RJG’s Medical Molding Symposium focuses on helping companies deal with the very expensive and time/resource consuming task of meeting FDA requirement for IQ, OQ and PQ. Medical molders face a unique and growing set of challenges. FDA guidelines must be met and quality must be maintained, but at the same time ways to reduce costs associated with documentation and inspection must be reduced. For more information on this free seminar or to register click here.

MAPP Survey on Cavity Pressure Technology
There is much discussion these days about the investment needed to produce a perfect injection molded part, the first time, every time, no matter what the volume.  With these discussions, there are a variety of view points about the investment and payback of utilizing Cavity Pressure Transducer technology in order to achieve a zero defect free molding environment. In March, MAPP conducted a brief survey on Cavity Pressure Technology. Over 75 different companies participated in the survey. From the feedback received in this survey, numerous reasons exist for the adoption of (or at least the consideration of the use of) pressure sensors. Toping the list of reasons for technology implementation is the need to reduce scrap levels while improving product quality.  With this said, some survey respondents desired more process control while relying less on quality / operator inspections to catch defects like short shots, flash, dimensional stability, and other part variation problems encountered with multi-cavity molding. Overall, it appears that injection molders using the Cavity Pressure Technology are satisfied with the results they are experiencing; 92% of those using the technology indicated that the technology has either been Very helpful or Somewhat helpful in improving overall part quality. To emphasize this point, one survey participant explained that "you don't know what you don't know until you see it from the plastic's point of view - where applicable, cavity pressure technology is a no-brainer." More
MAPP Website

Share the RJG Value with Your Customers
Do your customers need help understanding the value you bring them through your investment in RJG training and technology? Are there communication frustrations because your customers don’t “speak your scientific molding language”? Does your sales force need to better understand the value your RJG investment will bring to potential new customers? We can provide you with information about applicable RJG educational events or webinars they can attend (often at no charge). Or we can schedule a customized event tailored to your organization. Contact training@rjginc.com.

Upcoming Events
Date Event Booth # Location
April 22 New Strategies for Lean Injection Molding
Pewaukee, WI
April 29 Process Monitoring and Control
for Medical Molders
- Webinar
May 12 RJG Medical Molding Symposium
Ogden, UT
June 22-26 NPE 2009 8018 Chicago, IL
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