Supervisors benefit from a broad understanding of materials, processing and part quality control issues. Paul offers two seminars to help:

  • ‘Doing It Right the First Time’
  • Ten Areas to Save Costs & Energy in Rotomolding

Supervisor Course 1:

‘Rotomolding: Doing it Right the First Time’

This is a broad-based seminar for a Company Wide audience aimed at helping molders avoid problems in production and with customer-related issues. Originally written to help molders avoid legal issues by implementing good practices, the seminar addresses important aspects of molding that are sometimes overlooked or not considered important until it is too late.

Course Objectives:

  • Highlight how good practices in production prevent downstream failures.
  • Show the relationship between early decisions and long-term performance of products
  • Reinforce the need for good documentation; clear understanding of responsibilities and product validation.

Key Areas Covered Include:

1. Typical Problems and Law-Suits Faced by Molders

  • Common complaints and issues and the broader effect that such problems cause

2. Product Performance Requirements

  • Not all customers know exactly what they need - their specifications and requirements may not be enough

3. Establishing a Contract with Customers / End-Users

  • Defining who does what, when and where so that if something goes wrong, responsibilities are clear

4. Good Design Practice

  • Following some simple ‘golden rules’ for rotomolding eliminates problems in production and in-service

5. Validation of Production vs. Design

  • Making sure that you produce what you say you are producing – the 1st part approval process

6. Understanding Materials and Long-Term Performance

  • Selecting the right material for the application requirements – which properties are the most critical?

7. Good Process Control

  • Understanding what can be controlled and how helps develop the key steps required to ensure consistency

8. Documentation

  • Good data + good records = good defense

9. Identify Problems Early

  • QC steps in production which will help prevent faulty products from leaving your facility, improve scrap rates and save money

10. Testing of Materials and Parts

  • Good quality procedures to check incoming materials are essential as well as effective validation of final parts

Duration: This is a full-day seminar with around 6-7 hours of instruction

Group Size: Ideal group is 7-12 people for best interaction. Larger groups can be accommodated (up to 20 or more) if required but interaction will be reduced.

Supervisor Course 2:

‘Ten Areas to Save Costs & Energy in Rotomolding’

This course is aimed at Production Staff offering practical tips and ideas for immediate use on the shop-floor.

Course objectives: Provide ideas and insights into practical issues faced by operators and supervisors in production.

Improve operator knowledge to show improvements in processing time and practical, common sense troubleshooting.

Generate positive, short-term results with immediate cost savings, improved efficiencies and less scrap.

Allow discussion on company-specific problem areas and brainstorming on possible solutions.

Key Topics:

1.  Process Optimization

  • Fundamental Control Principles, Options for Molders, Key Control Points, Effect of Time/Temperature, Optimizing Performance

2. Productivity – Scheduling

  • The Importance of Rhythm, Machine Styles, Scheduling Issues and Tips, Servicing of Molds & Parts

3. Lean Manufacturing for Rotomolding

  • Overview of Key Elements, Why Rotomolding is Inherently Lean, Developing an Improvement Plan

4. Material Selection

  • Grade choices, Effect on Processing Speed, Grinding, Material Strength vs. Requirements and Long-Term Properties

5. Part Release

  • Basic principles, Available types, Good Practices, Effects & Processing Issues

6. Venting of Molds

  • Theory, Problems Caused, Options Available, Good Practices

7. Oven Efficiency

  • Fan/Burner/Blower Capacities, Tuning of Ovens, Oven Elements, Energy Saving Tips

8. Cooling Cycles

  • Methods Available, Rates of Cooling vs. Material Properties, Practical Issues

9. QC Inspection of Parts

  • Objectives, Part Inspection Tips, Data Capture, Tolerances, Scrap Reduction Tips

10. Troubleshooting

  • Common Problems for Molders, Suggested Solutions & Tips

This course can be combined with reviews of current shop-floor operations and discussion on issues and challenges currently being faced by production staff.

Duration: Full-day session (approximately 5-6 hours of instruction and 1-2 hours of question and answers)

Group Size: Ideal group is 7-12 people for best interaction. Larger groups can be accommodated (up to 20 or more) if required but interaction will be reduced.