Nowadays, companies in general, and those focused on extrusion and plastic injection, have specific metrics that tell us whether we are heading in the right direction and moving quickly enough to achieve the goals. As production managers, we participate in meetings (weekly, monthly, etc.) where we ask ourselves how we can counteract effects that are preventing us from improving our results or how to optimize projects to achieve a better use of resources: people, machine-time, materials.
Morale and rotation are two KPIs related to the resources provided within a company that allow personnel to have a fruitful and simple day's work. Although it can be challenging, companies must give their personnel peace of mind that they are in a safe environment, that their effort really drives the company, and that the company values them as individuals.
Machines must be as efficient as possible to make the best use of time, produce more parts and have the capacity for new business. Of course, we mustn’t forget the time that the machine requires for maintenance.
Lastly, think of the use of the raw material, achieving the transformation of each of the direct materials received into a finished product, and avoiding all waste.
These are a few factors to consider when evaluating the acquisition of new technologies such as purge compounds; considering how these impact the plant's objectives and not just its unit price.
Let's see how two purge compounds can affect long-term metrics.
During weekly production, we have product changes in which we routinely use purgatives that allow us to change color, resin and clean casting molds. By using purge compounds, we reduce dead time, resin waste and we free up personal to perform other activities. In some cases, this has reduced waste from 10% to 2%.
Stoppages for assembling molds, periods without production programs, stoppages, holidays and weekends are opportunities for the purgative to work and help us prevent the formation of contamination due to degradation. This prevents the machines from getting dirty and reduces the frequency with which it is necessary to remove the screws. This translates into easier startups, less damage to equipment, greater control over the production schedule and improved safety for personnel. Plants where screws were removed up to 4 times a month have been able to stop doing so and switch to a monitored program, removing the screws every 6 months or annually.
After a longer period, such as a year, it is recommendable to carry out scheduled preventive maintenance to remove the screw, clean it, check it and change the parts that need changing. The use of certain purge compounds can help to do this in half the time and avoid the use of flames, which puts personnel at risk and causes a lot of damage to the screw. This translates into a virtuous circle in which we have a good machine, good tools and the conditions for growth.
Ready to reduce your production downtime to protect your profits? Learn more about how purging compounds and process efficiency work in tandem.