The Plastics Training Specialists

Scientific Molding 102

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Scientific Molding 102 builds on the knowledge base established in Injection Molding 101.

This online plastics training package provides a great wealth of information to augment the knowledge of any processor, technician, or die setter.

Package Course Descriptions:

Process Documentation for Scientific Molders

This training program will provide participants with a better understanding of proper documentation and the procedures associated with documenting a scientific molding process.

The comprehensive course teaches the differences between machine-dependent and machine-independent process parameters as well as the importance of proper documentation for each. Students will also learn the necessary procedures associated with documenting and maintaining a robust scientific molding process.

- the Definition of scientific process documentation
- Inputs vs. Outputs
- Machine-Dependent Documentation
- Machine-Independent Process Documentation
- Documenting Barrel & Recovery
- Documenting 1st Stage Injection
- Documenting 2nd Stage Packing
- Documenting Part Cooling
- Documenting Mold Clamping
- Hybrid Machine & Process Documentation
- Documenting All Process Changes

Processing Parameters for Scientific Molding

This 3-part training program will provide participants with a better understanding of the parameters involved with a scientific injection molding process and the control panels of injection molding machines.

This course is beneficial to die setters, process technicians, maintenance personnel, engineers, and anyone else using the control panel.

Part 1 - Introduction
- Scientific Molding Overview
- 5 General Rules for Scientific Molding
- Understanding the Process Controller
- Common Units for Process Parameters

Part 2 - Process
- Process Inputs versus Process Outputs
- 1st Stage Injection Inputs and Outputs
- 2nd Stage Packing Inputs and Outputs
- Cooling Inputs and Outputs
- Screw Recovery Inputs and Outputs
- Other Commonly Found Process Inputs

Part 3 - Part Removal
- Mold Open Settings
- Part Ejection Settings
- Core Pull Settings
- Mold Closing Settings

Injection Mold Setup

This comprehensive 2-part program provides participants with a better understanding of die setting including safety preparation, documentation, mold removal & installation, and process startup. This is an excellent course for anyone involved in die setting including process technicians and supervisors.

Injection Mold Setup, Program 1
- Safety Concerns and Considerations for Die Setters
- Injection Mold Setup Scheduling and Preparation
- Machine Dependent and Independent Documentation
- Proper Injection Mold Preparation and Examination
- Safe and Effective Mold Removal Techniques

Injection Mold Setup, Program 2
- Safe and Effective Mold Installation Techniques
- Setting Clamp Tonnage and Mold Protect
- Optimizing Clamp and Part Ejection Settings
- Establishing Consistent Screw Recovery
- Melt Temperature Matching Techniques
- Process Startup and Scientific Molding Principles

Automation and Robotics for Scientific Molders

This comprehensive 2-part program provides participants with a better understanding of how automation and robotics are used to streamline production within the injection molding industry. Using standard industry terms and practices with an emphasis on safety, this series will enhance the knowledge base of all production personnel involved with automation and robotics.

Automation and Robotics, Program 1
- General Automation & Robotics Safety
- Common Guarding for Automation & Robotics
- Common Automation for Injection Molding

Automation and Robotics, Program 2
- Controllers & Movements of Robotics
- End-of-Arm Tooling
- Sprue Pickers
- Top-Entry Robots
- Side-Entry Robots
- Articulating Robots
- Examples of Robotics

Material Drying Technology

Routsis Training’s two Material Drying Technology online courses provide participants with a better understanding of how different polymers are best dried and prepared for reliable processing. These courses show participants how proper plastics material handling and drying is critical to produce a consistent product and process. Course One reviews polymer basics, as well as both hygroscopic and non-hygroscopic polymers – to better convey the importance of properly drying water-sensitive materials.

Material Drying Technology, Course 1
- Polymer Basics
- Hygroscopic vs. Non-Hygroscopic Polymers
- Hydrolysis
- Purposes of Drying
- Dewpoint
- Dewpoint Measurement
- Dewpoint Sensors
- Drying Procedures

Material Drying Technology, Course 2
- Hot Air Dryers
- Compressed Air Dryers
- Desiccant Dryers
- Vacuum Dyers
- Calculating Material Consumption
- Calculating Residence Time
- Calculating Dryer Capacity

Electric Injection Molding

Our two Electric Injection Molding courses will provide participants with a better understanding of the benefits and capabilities of modern all-electric injection molding machines. Safety concerns particular to electric molding machines are also covered.

Course 1: Understanding Electric Injection Molding Machines

This training program will provide participants with a better understanding of how electric injection molding machines function – as well as the many benefits and capabilities associated with electric molding machines.

- General Injection Molding Safety
- Electric Molding Machine Safety
- Machine Guarding
- Comparing Hydraulic and Electric Machines
- Basic Molding Machine Functions
- Efficiency, Accuracy and Repeatability
- Alternative Machine Designs
- Typical Uses for Electric Injection Molding Machines

Course 2: Processing with Electric Injection Molding Machines

Packed with in-depth processing information, this course will undoubtedly prepare processors for making more appropriate and cost-effective decisions. Participants will also learn how to optimize any process that’s running on an electric injection molding machine.

- Closed-Loop Process Controls
- Hydraulic vs. Electric Molding Machine Controls
- Process Optimization Strategies:
- 1st Stage Filling
- 1st Stage to 2nd Stage Transfer
- 2nd Stage Pack
- Screw Delay
- Screw Recovery
- Screw Decompression
- Cooling Time
- Mold Opening
- Part Ejection
- Mold Closing
- Clamping

Math for Molders

This two-part training program was created for all personnel within the injection molding industry who would like to expand or fine-tune their math skills.

These courses will greatly benefit any participant of RJG’s classroom-based Master Molder SM Certification Series either as a primer or as follow-up training.

Part 1
- Whole Numbers, Negative Numbers and Decimals
- Using a Calculator
- Addition, Subtraction, Multiplication and Division
- Rounding Numbers and Significant Figures
- Formulas, Equations and Order of Operations

Part 2
- Metric and Imperial Units
- Length and Distance
- Area, Volume & Flow
- Weight, Mass and Force
- Conversions
- Understanding Percentages
- Calculating Plastic Pressure and Part Shrinkage
- Calculating Tolerances

5S SkillSet™ Series

The 5S System SkillSet™ Series is a unique learning experience that combines detailed, step-by-step online instruction with practical hands-on labs and worksheets.

Each of the five course/worksheet combinations focuses on developing important Lean Manufacturing related skills that translate directly to any production or workplace environment.

This exclusive training approach allows companies to perform the same type of classroom learning found in popular seminars in the comfort of their own production environment. Your employees will develop effective 5S Skills so they can contribute directly to and help maintain your Lean Manufacturing efforts.

Each unique training course is a blend of the following components:

Your technicians understand the goal of each 5S SkillSet™

Technicians learn specifically how each 5S SkillSet™ applies

Items are detailed to ensure techs have the tools they need to succeed

Each step is demonstrated so your techs can proceed with confidence

Contains all the information your techs need to succeed with each 5S SkillSet™

What’s Covered in the 5S Skillset™ Series?

The 5S SkillSet™ labs teach a sound approach to Lean Manufacturing. With 5 distinct skills being taught, your technicians can quickly learn how to apply proven Lean Manufacturing techniques to the everyday production environment.

Your processors and technicians will receive hours of online SkillSet™ instruction and hands-on labs to confidently develop the following abilities:

Step 1: Sorting

In the 5S System, the Sorting step’s goal is to eliminate all unnecessary items from the immediate workplace. This is done by sorting the workplace to determine what to keep, what to toss, and what to store. This helps prevent clutter from interfering with everyday production activities.

Step 2: Straightening

At the end of the Straightening step, everything in the workplace is neatly organized; resulting in a more convenient and more efficient workplace.

Step 3: Sweeping

In the Sweeping step, the best method for cleaning each selected area in the workplace is determined. A reasonable cleaning schedule should also be determined to ensure the workplace remains efficient, clean and organized.
Step 4: Standardizing

The goal of the Standardizing step is to achieve consistency. A similar appearance and layout should be applied to all workstations whenever possible. This step is often performed after a similar workplace or area within the plant has already been straightened.

Step 5: Sustaining

The purpose of the Sustaining step is maintenance. This is achieved by a review of the workplace and the existing Sorting and Straightening documentation – to ensure the workplace is efficient and up-to-date. This helps identify necessary materials or equipment that have been added to the workplace but have not yet been incorporated into the 5S documentation.

Purging for Scientific Molders Series

The four courses in Routsis's Purging training program will teach scientific injection molders about proper material purging concepts and procedures.

The first two courses cover common purging techniques and effective purging procedures – while the third course details common types of purging compounds, how they work, and the advantages and disadvantages of each type. In the final course, users are shown how to effectively compare different purging procedures and compounds – and guided through completion of the accompanying Purging Analysis Worksheet.

Purging Techniques
- Definition of Purging
- General Injection Molding Safety
- Injection Molding Machine Safety
- Plastic Purging Safety
- The Purpose of Purging
- Small vs. Large Shot Purging
- Continuous and Closed-Mold Purging
- Dry vs. Wet Purging
- Purging Heat Sensitive Materials
- Purging High Temperature Materials
- Hot Runner and Gate Drop Cleaning
- Nozzle and Screw Removal

Purging Procedures
- Phase 1 – Preparation
- Phase 2 – Initial Purging
- Phase 3 – Final Purging
- Phase 4 – Production

Purging Compounds
- Common types of Compounds
- Resin-Based Purging Compounds
- Mechanical Purging Compounds
- Chemical Purging Compounds

Purging Cost Analysis Worksheet
- Purging Compound Cost
- Machine Downtime Cost
- Purging Labor Cost
- Final Production Resin Cost
- Scrap and Rework Costs

23 Online Courses (20-40 hours + Study Guides & Worksheet)