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MAPP Plastics Discussion Forum

The MAPP Plastic Industry Discussion Forum allows members to rapidly communicate with each other. Post both questions and answers to questions that other MAPP members have about any industry topic from material and process issues to R&E Tax Credits and other business issues.

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Posted:  18 Mar 2016 17:33
i'm sure this conversation has already been on here but I would like to start it again.  I would like to learn how others are capturing/reporting scrap using IQMS.  we have been unable to find an accurate method that is not operator dependent. 

One method we tried was to create a report that captures the actual machine cycles versus the parts going to the warehouse to get overall scrap.  With this, the issue becomes when the scheduled job is actually changed over on the system.  If the supervisor is an hour or two late, for example, false data occurs.

Another method was to have the operators record the scrap from their machines and provide to supervisor towards end of the shifts so it could be entered into the production report.  this failed and was inaccurate due to being operator dependent.

any thoughts are welcome

Posted:  22 Mar 2016 00:02
Do you have RT stations? Allowing operators to input  scrap on an rt station may help and make them feel more engaged.

The next level is to make sure the machine parameters are set and tie that into the real time module reject signal. You can also tie an e-dart into the real time module for scrap dispositioning.

If you load jobs in first position prior to qa approving them that throws off the counts also unless the scrap is accounted for. If you have the signal tied into mold closed instead of inject forward when in auto that can throw counts off aswell.

No matter what is done it requires a level of strong discipline  whether it is the team lead/supervisor entering scrap everyshift/hour/realtime or a technician who has to set alarms in the machine and make sure the are consistent with failure modes.

I think this daily data entry and scrap dispositioning is one of the hardest parts of IQ but it would be with any system.

Posted:  22 Mar 2016 21:46
Thanks Bradley,  We do not have the RT stations at each press.  We feel that if the operators are not accurate at writing down the scrap, the RT station wouldn't help.  We'll give it some thought. 

That's good to know about the Edart capability.  unfortunately, we do not have Edarts at every press and with that, most of our jobs are smaller runs which complicates it all.  It's not uncommon for us to change out 10 molds a day.


Posted:  23 Mar 2016 14:08
Smaller runs are the most difficult as you can purge  the entire run sometimes. Changing the scrap rate in IQ may help. Other than that its diligence in reporting if you stumble across something else let us know as we have this issue pop up every now and again also.
Posted:  31 Mar 2016 18:14
We have the same issues. We have operators keep track on paper of all the rejects and the production report is dispositioned at the end of every shift. We too have "unreported rejects". Most of the time this is attributed to the operator not keeping track of everything as they should. There doesn't seem to be an easy way to capture this data correctly.

Our RT signals are generated on BOTH a mold close and inject forward. A signal doesn't generate if only one is triggered.

Eddie Knapp
Posted:  05 Apr 2016 21:08
Scott, TPI uses RT to record cycles. We focus on the good parts to secure our counts on each shift. We then deduct the reported scrap that the operators captured. Anything still showing up as missing we enter again as scrap. This scrap is generated from dry cycles or any other parts that did not end up as part that was accounted for. Here is how it looks.

TOTAL PARTS PRODUCED - GOOD PARTS - KNOWN SCRAP. This then gives you Zero unaccounted for parts or missing parts. If you have missing part they must be entered as scrap for IQMS to adjust your WO.

Hope this helps.

Posted:  05 Apr 2016 22:19
Thanks Jeff.  This is pretty much the same as we do.  We take the total machine cycles minus the disposition parts to give us the scrap.  We simply compare this calculated scrap to the reported scrap.  This issue becomes of when the jobs(WO)is loaded in the system.  If not done at the correct moment and the next mold is started, the scrap is then reported on the previous job.  We realize this is human error on supervisors and are trying to find a fail-safe method.

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