Plastics are used in numerous applications and products around the world, including building and construction, textiles, consumer products, transportation, electronics, and industrial machinery. Lean and Six Sigma methodologies are used to improve quality and reduce waste in plastics manufacturing. We’ll look at three applications from India and Kuwait and finish with an instructional video on the seven types of plastics.


Reduction of Changeover Times using Six Sigma and Lean Tools: India


In a paper titled “Process Improvement in a Plastic Manufacturing Industry using Six Sigma Tools,” author Kaustubh Kale discusses the use of Six Sigma and Lean tools to reduce the changeover times for molds, tools, and dies.

The paper includes:

  • Project Charter
  • Cause and Effect Diagram for Changeover Time
  • Pareto Chart of Changeover Times by Activity
  • Run Charts of Changeover Times by Activity
  • Capability Analysis of Activities
  • Mold Storage Areas Before and After
  • Total Changeover Times Before and After

You can read the paper here.


Six Sigma Methodology Applied to Reduce Part Rejection Rate: India


In a case study titled “Six Sigma Methodology In A Plastic Injection Molding Industry: A Case Study,” authors Ashish Mishra, Pankaj Mishra and Sachendra cover the use of Six Sigma methodology to reduce the part rejection rate.

The case study includes:

  • In Line Rejection by Part: Data and Pareto Chart
  • Reject Data by Defect Type: Data and Pareto Chart
  • Potential Causes for High Defects
  • Cause and Effect Diagram for Black Dot Defect
  • Run Chart for Black Dot Defect Before and After Screw Barrel Cleaning

You can read the case study here.


Using Lean Six Sigma to Reduce the Injection Molding Part Defect Rate: Kuwait


In a paper titled “Quality Improvement in Plastic Injection Molding Industry: Applying Lean Six Sigma to SME in Kuwait,” authors Alaa Alshammari and others discuss the use of Lean Six Sigma to reduce the part defect rate.

The paper includes:

  • Swimlane Flowchart
  • Attribute Agreement Analysis
  • Pareto Chart of Defects
  • Fishbone Diagram for Defective Parts
  • Cause and Effect Matrix
  • Experimental Design and Analysis
  • Action Plan
  • Bar Chart of Before and After Improvements

You can read the paper here.


The Seven Types of Plastics


Learn about the seven types of plastics in this video from Plascon Plastics, a Canadian Corporation and a leader in the injection molding plastics industry.

You can watch the video here.




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