Injection Moulding Tool Trial Report V3.0

• Trial #

  Select T1 T2 T3 T4 Pre-Grain Post-Grain

  • T1
  • T2
  • T3
  • T4
  • Pre-Grain
  • Post-Grain

• Have all previously identified issues been resolved?

  Yes

  No

• Have all previously identified issues been resolved?

  Yes

  No

• Have all previously identified issues been resolved?

  Yes

  No

• Have all previously identified issues been resolved?

  Yes

  No

• Have all previously identified issues been resolved?

  Yes

  No

• Customer

• Tycos Job #

• Division Tool #

• Program Name

• Part Number

• Part Description

• Conducted on

  Date

• Completed by

• Trial Location Name

• Trial Location
  Address

• Type of Facility

  Production Facility

  Supplier

  Trial Shop

  Other (Identify in Notes)

• Sample Type

  Select 1st Shots Final Verification Issue Verification Part Run Run @ Rate DOE Support

  • 1st Shots
  • Final Verification
  • Issue Verification
  • Part Run
  • Run @ Rate
  • DOE
  • Support

• Tool Builder Name

• Tool Builder Job #

• Tycos Program Manager Present?

  Yes

  No

  Represented

  Virtual / Online

• Tycos Program Manager Name

• Tycos Program Manager Representative Name

• Tycos Program Manager Name

• Tool Builder Program Manager Present?

  Tycos Built

  Yes

  No

  Represented

  Virtual / Online

• Tool Builder Program Manager Name

• Tool Builder Program Manager Representative Name

• Tool Builder Program Manager Name

• Plant Tool Engineer Present?

  Yes

  No

  Represented

  Virtual / Online

• Plant Tool Engineer Name

• Plant Tool Engineer Representative Name

• Plant Tool Engineer Name

• Plant Program Manager Present?

  Yes

  No

  Represented

  Virtual / Online

• Plant Program Manager Name

• Plant Program Manager Representative Name

• Plant Program Manager Name

• Plant Process Engineer Present?

  Yes

  No

  Represented

  Virtual / Online

• Plant Process Engineer Name

• Plant Process Engineer Representative Name

• Plant Process Engineer Name

• Plant Quality Engineer Present?

  Yes

  No

• Plant Quality Engineer Name

• Moldflow Analyst Present?

  Yes

  No

• Moldflow Analyst Name

• Material Supplier Present?

  Yes

  No

• Material Supplier Name

• Additional People Present at the Trial

• Observations About the Trial Facilities and Attendees

Physical Units

• Select All Physical Units Used For This Report

• Temperature Units

  Farenheit (F)

  Celsius (C)

• Position Units

  Millimeter (mm)

  Inches (in)

• Pressure Units

  Psi

  Bar

  Kpa

  Kg/cm^3

• Weights

  Pounds (lbs)

  KiloGrams (Kg)

• Clamp Force Units

  Metric Tons (Mtons)

  US Tons (UStons)

  KiloNewton (KN)

Reference Documents

• Take Photo of Valve Gate Layout if Available

  Media

Resin Details

• Resin Manufacturer

• Resin Grade - (3325, 342EZ, etc)

• Resin Type - (PP, PC/ABS, Acetal, etc)

• Multiple Colours?

  Yes

  No

• Colour Code (If Required)

• Resin Dry Time - (hrs)

• Resin Dry Temperature

• Target Shrink Rate - (mm/1000)

• Take Photo of Material Label

  Media

Machine Details

• Name of Press

• Intensification Ration - (# : 1)

• Screw Diameter - (mm)

• Barrel Size - (grams)

• Tonnage of Press

• Projected Tonnage

• Actual Tonnage

• Clamp Style

  Select Hydraulic Ram Hydraulic Toggle Electric Toggle Two Platen Hydra-mechanical Electric Servo Other

  • Hydraulic Ram
  • Hydraulic Toggle
  • Electric Toggle
  • Two Platen Hydra-mechanical
  • Electric Servo
  • Other

• Observations About The Resin and Machine Details

• For the T1 trial , the mould flow report should be used for the process inputs. For all subsequent trials, use the process inputs from the previous trial

• Trial #

  Select T1 T2 T3 T4 Pre-Grain Post-Grain

  • T1
  • T2
  • T3
  • T4
  • Pre-Grain
  • Post-Grain

• Is There Another Process With Targets For This Trial?

  Yes

  No

• Reference Process Intensification Ratio - (#:1)

• Reference Process Screw Diameter - (mm)

• Target Melt Temperature

• Target Cavity Steel Temperature

• Target Core Steel Temperature

• Target Hot Runner Temperature

• Target Fill Time (Seconds)

• Target Hold Pressure

• Target Hold Time

• Target Recovery Time

• Target Cooling Time

• Target Part Weight - Zero Hold at Transfer

• Target Part Weight - Fully Packed Part

• Include Picture of Reference Process Sheet

  Media

• Is There Another Process With Targets For This Trial?

  Yes

  No

• Reference Process Intensification Ratio - (#:1)

• Reference Process Screw Diameter - (mm)

• Target Melt Temperature

• Target Cavity Steel Temperature

• Target Core Steel Temperature

• Target Hot Runner Temperature

• Target Fill Time (Seconds)

• Target Hold Pressure

• Target Hold Time

• Target Recovery Time

• Target Cooling Time

• Target Part Weight - Zero Hold at Transfer

• Target Part Weight - Fully Packed Part

• Include Picture of Reference Process Sheet

  Media

• Is There Another Process With Targets For This Trial?

  Yes

  No

• Reference Process Intensification Ratio - (#:1)

• Reference Process Screw Diameter - (mm)

• Target Melt Temperature

• Target Cavity Steel Temperature

• Target Core Steel Temperature

• Target Hot Runner Temperature

• Target Fill Time (Seconds)

• Target Hold Pressure

• Target Hold Time

• Target Recovery Time

• Target Cooling Time

• Target Part Weight - Zero Hold at Transfer

• Target Part Weight - Fully Packed Part

• Include Picture of Reference Process Sheet

  Media

• Is There Another Process With Targets For This Trial?

  Yes

  No

• Reference Process Intensification Ratio - (#:1)

• Reference Process Screw Diameter - (mm)

• Target Melt Temperature

• Target Cavity Steel Temperature

• Target Core Steel Temperature

• Target Hot Runner Temperature

• Target Fill Time (Seconds)

• Target Hold Pressure

• Target Hold Time

• Target Recovery Time

• Target Cooling Time

• Target Part Weight - Zero Hold at Transfer

• Target Part Weight - Fully Packed Part

• Include Picture of Reference Process Sheet

  Media

• Is There Another Process With Targets For This Trial?

  Yes

  No

• Reference Process Intensification Ratio - (#:1)

• Reference Process Screw Diameter - (mm)

• Target Melt Temperature

• Target Cavity Steel Temperature

• Target Core Steel Temperature

• Target Hot Runner Temperature

• Target Fill Time (Seconds)

• Target Hold Pressure

• Target Hold Time

• Target Recovery Time

• Target Cooling Time

• Target Part Weight - Zero Hold at Transfer

• Target Part Weight - Fully Packed Part

• Include Picture of Reference Process Sheet

  Media

• Was a Mould Flow Completed For This Tool?

  Yes

  No

• Mould Flow Theoretical Starting Points

• Mould Flow Report File Name

• Target Melt Temperature

• Target Cavity Steel Temperature

• Target Core Steel Temperature

• Target Fill Time (Seconds)

• Target Fill Speed - (cm^3/sec)(Still need to match fill time)

• V/P Control Metric - ##% Volume Filled Before Transfer

• Pack and Hold Time

• Pack and Hold Target Pressure - Plastic Pressure

• Pack and Hold Target Pressure - % of V/P Transfer Pressure

• Gate Freeze Time

• Cooling Time Target

• IPC (Injection, Pack, and Cooling) Time Target

• Valve Gate Trigger Reference Map

  Media

• Valve Gate Sequence Target Settings

  Media

• Is There Another Process With Targets For This Trial?

  Yes

  No

• Reference Process Intensification Ratio - (#:1)

• Reference Process Screw Diameter - (mm)

• Target Melt Temperature

• Target Cavity Steel Temperature

• Target Core Steel Temperature

• Target Hot Runner Temperature

• Target Fill Time (Seconds)

• Target Hold Pressure

• Target Hold Time

• Target Recovery Time

• Target Cooling Time

• Target Part Weight - Zero Hold at Transfer

• Target Part Weight - Fully Packed Part

• Include Picture of Reference Process Sheet

  Media

Process Inputs

Temperatures

Barrel Temperatures

• Rear Zone

• Middle Zone 1

• Middle Zone 2

• Middle Zone 3

• Front Zone

• Barrel Head / Adaptor

• Nozzle

• Take Photo of Barrel Heat Profile

  Media

Hot Runner Temperatures

• Number of Hot Runner Zones

• Are All Zones Set to the Same Temperature?

  Yes

  No

• Define which zones are different, the temperature, and the reason why.

• Temperature of All Zones

• Is the Hot Runner Manifold Working Properly as it was Intended?

  Yes

  No

• Take a Photo of All Hot Runner Manifold Issues and Create an Action Item

  Media

• Take Photo of the Hot Runner Screen

  Media

Tool Temperatures

• Target Number of Cavity Water Zones

• Number of Cavity Water Zones Used

• Cavity Zone 1 Temperature

• Cavity Zone 2 Temperature

• Cavity Zone 3 Temperature

• Cavity Zone 4 Temperature

• Cavity Zone 5 Temperature

• Target Number of Core Water Zones

• Number of Core Water Zones Used

• Core Zone 1 Temperature

• Core Zone 2 Temperature

• Core Zone 3 Temperature

• Core Zone 4 Temperature

• Core Zone 5 Temperature

• Number of Auxiliary Water Zones

• Auxiliary Zone 1 Temperature

• Auxiliary Zone 2 Temperature

• Auxiliary Zone 3 Temperature

Injection Profile

• Take Photo of Injection Profile

  Media

• If Injection Speed is in %, What is the Maximum Physical Speed?

• If Injection Pressure is in %, What is the Maximum Physical Pressure?

Pack / Hold Profile

• Take Photo of Pack/Hold Profile

  Media

• If Pack/Hold Pressure is in %, What is the Maximum Physical Pressure?

Recovery Profile

• Take Photo of Recovery Profile

  Media

• If Back Pressure is in %, What is the Maximum Physical Pressure?

• If Screw Speed is in %, What is the Maximum Physical Screw Speed?

Valve Gates

• Valve Gate Type

  Hydraulic

  Pneumatic

  None

• Number of Valve Gates

• Valve Gate Trigger for Injection

  Position

  Time

  Temperature Sensor

  Pressure Sensor

• Take Photo of Valve Gate Injection Settings

  Media

• Take Photo of Valve Gate Pack/Hold Settings

  Media

Valve Gate Speed Monitoring

• Are You Able to Monitor the Valve Pin Opening Times With a Synventive Valve Monitoring Interface Module?

  Yes

  No

• Number of Valve Gates Monitored

• Valve Pin 1 Opening Time (sec)

• Valve Pin 2 Opening Time (sec)

• Valve Pin 3 Opening Time (sec)

• Valve Pin 4 Opening Time (sec)

• Valve Pin 5 Opening Time (sec)

• Valve Pin 6 Opening Time (sec)

• Valve Pin 7 Opening Time (sec)

• Valve Pin 8 Opening Time (sec)

• Valve Pin 9 Opening Time (sec)

• Valve Pin 10 Opening Time (sec)

• Valve Pin 11 Opening Time (sec)

• Valve Pin 12 Opening Time (sec)

• Valve Pin 13 Opening Time (sec)

• Valve Pin 14 Opening Time (sec)

• Valve Pin 15 Opening Time (sec)

• Valve Pin 16 Opening Time (sec)

• Valve Pin 17 Opening Time (sec)

• Valve Pin 18 Opening Time (sec)

• Valve Pin 19 Opening Time (sec)

• Valve Pin 20 Opening Time (sec)

• Valve Pin 21 Opening Time (sec)

• Valve Pin 22 Opening Time (sec)

• Valve Pin 23 Opening Time (sec)

• Valve Pin 24 Opening Time (sec)

• Attach Pictures of All Valve Pin Monitoring Times

  Media

• Observations About Process Inputs

Process Outputs

• Melt Temperature

• Maximum Injection Pressure

• Injection Pressure at V/P Transfer

• Full Shot Stroke

• V/P Transfer Position

• Cushion Position

• Take a Photo of the Process Output Screen

  Media

Process Timers

• Target Production Cycle Time (sec)

• Actual Cycle Time (sec)

• If Cycle Time Is Not Within 2 Seconds of the Target, Briefly Explain Why Not.

• Clamp Opening Time (sec)

• Clamp Closing Time (sec)

• Injection Time (sec)

• Hold Time (sec)

• Cooling Time (sec)

• Recovery Time (sec)

• Take a Photo of the Cycle Time Breakdown Screen

  Media

Part Weights and Measurements

• Number of Cavities

• Zero Hold Weight

• Full Weight

• Scribe Line Measurement - What is the Scribe Scale?

  250 mm

  500 mm

  750 mm

  1000 mm

  N/A

• Scribe Line Measurement

• Runner Weights

• Zero Hold Weight - Cavity 1 (Left)

• Zero Hold Weight - Cavity 2 (Right)

• Full Weight - Cavity 1 (Left)

• Scribe Line Measurement - Cavity 1 (Left) - What is the Scribe Scale?

  250 mm

  500 mm

  750 mm

  1000 mm

  N/A

• Scribe Line Measurement

• Full Weight - Cavity 2 (Right)

• Scribe Line Measurement - Cavity 2 (Right) - What is the Scribe Scale?

  250 mm

  500 mm

  750 mm

  1000 mm

  N/A

• Scribe Line Measurement

• Runner Weights

• Zero Hold Weight - Cavity 1

• Zero Hold Weight - Cavity 2

• Zero Hold Weight - Cavity 3

• Full Weight - Cavity 1

• Scribe Line Measurement - Cavity 1 - What is the Scribe Scale?

  250 mm

  500 mm

  750 mm

  1000 mm

  N/A

• Scribe Line Measurement

• Full Weight - Cavity 2

• Scribe Line Measurement - Cavity 2 - What is the Scribe Scale?

  250 mm

  500 mm

  750 mm

  1000 mm

  N/A

• Scribe Line Measurement

• Full Weight - Cavity 3

• Scribe Line Measurement - Cavity 3 - What is the Scribe Scale?

  250 mm

  500 mm

  750 mm

  1000 mm

  N/A

• Scribe Line Measurement

• Runner Weights

• Zero Hold Weight - Cavity 1

• Zero Hold Weight - Cavity 2

• Zero Hold Weight - Cavity 3

• Zero Hold Weight - Cavity 4

• Full Weight - Cavity 1

• Scribe Line Measurement - Cavity 1 - What is the Scribe Scale?

  250 mm

  500 mm

  750 mm

  1000 mm

  N/A

• Scribe Line Measurement

• Full Weight - Cavity 2

• Scribe Line Measurement - Cavity 2 - What is the Scribe Scale?

  250 mm

  500 mm

  750 mm

  1000 mm

  N/A

• Scribe Line Measurement

• Full Weight - Cavity 3

• Scribe Line Measurement - Cavity 3 - What is the Scribe Scale?

  250 mm

  500 mm

  750 mm

  1000 mm

  N/A

• Scribe Line Measurement

• Full Weight - Cavity 4

• Scribe Line Measurement - Cavity 4 - What is the Scribe Scale?

  250 mm

  500 mm

  750 mm

  1000 mm

  N/A

• Scribe Line Measurement

• Runner Weight

• Zero Hold Weight - Cavity 1

• Zero Hold Weight - Cavity 2

• Zero Hold Weight - Cavity 3

• Zero Hold Weight - Cavity 4

• Zero Hold Weight - Cavity 5

• Full Weight - Cavity 1

• Scribe Line Measurement - Cavity 1 - What is the Scribe Scale?

  250 mm

  500 mm

  750 mm

  1000 mm

  N/A

• Scribe Line Measurement

• Full Weight - Cavity 2

• Scribe Line Measurement - Cavity 2 - What is the Scribe Scale?

  250 mm

  500 mm

  750 mm

  1000 mm

  N/A

• Scribe Line Measurement

• Full Weight - Cavity 3

• Scribe Line Measurement - Cavity 3 - What is the Scribe Scale?

  250 mm

  500 mm

  750 mm

  1000 mm

  N/A

• Scribe Line Measurement

• Full Weight - Cavity 4

• Scribe Line Measurement - Cavity 4 - What is the Scribe Scale?

  250 mm

  500 mm

  750 mm

  1000 mm

  N/A

• Scribe Line Measurement

• Full Weight - Cavity 5

• Scribe Line Measurement - Cavity 5 - What is the Scribe Scale?

  250 mm

  500 mm

  750 mm

  1000 mm

  N/A

• Scribe Line Measurement

• Runner Weight

• Zero Hold Weight - Cavity 1

• Zero Hold Weight - Cavity 2

• Zero Hold Weight - Cavity 3

• Zero Hold Weight - Cavity 4

• Zero Hold Weight - Cavity 5

• Zero Hold Weight - Cavity 6

• Full Weight - Cavity 1

• Scribe Line Measurement - Cavity 1 - What is the Scribe Scale?

  250 mm

  500 mm

  750 mm

  1000 mm

  N/A

• Scribe Line Measurement

• Full Weight - Cavity 2

• Scribe Line Measurement - Cavity 2 - What is the Scribe Scale?

  250 mm

  500 mm

  750 mm

  1000 mm

  N/A

• Scribe Line Measurement

• Full Weight - Cavity 3

• Scribe Line Measurement - Cavity 3 - What is the Scribe Scale?

  250 mm

  500 mm

  750 mm

  1000 mm

  N/A

• Scribe Line Measurement

• Full Weight - Cavity 4

• Scribe Line Measurement - Cavity 4 - What is the Scribe Scale?

  250 mm

  500 mm

  750 mm

  1000 mm

  N/A

• Scribe Line Measurement

• Full Weight - Cavity 5

• Scribe Line Measurement - Cavity 5 - What is the Scribe Scale?

  250 mm

  500 mm

  750 mm

  1000 mm

  N/A

• Scribe Line Measurement

• Full Weight - Cavity 6

• Scribe Line Measurement - Cavity 6 - What is the Scribe Scale?

  250 mm

  500 mm

  750 mm

  1000 mm

  N/A

• Scribe Line Measurement

• Runner Weight

• Are the Scribe Line Measurements Within Tolerance?

  Yes

  No

• If Mould Flow Theoretical Starting Points Were Used, Did They Give an Accurate Prediction of the Required Process?

  Yes

  No

  Mould Flow Not Used

• Observations About Process Outputs and Weights

• Set the Transfer Position to Each of the Valve Gate Trigger Positions for Each Short Shot

• How Many Short Shot Stages Were Taken?

• 1st Transfer Position Set to?

• Fill Time at 1st Set Transfer Position

• Take Photo of 1st Transfer Short Shot

  Media

• 1st Transfer Position Set to?

• Fill Time at 1st Set Transfer Position

• Take Photo of 1st Transfer Short Shot

  Media

• 2nd Transfer Position Set to?

• Fill Time at 2nd Set Transfer Position

• Take Photo of 2nd Transfer Short Shot

  Media

• 1st Transfer Position Set to?

• Fill Time at 1st Set Transfer Position

• Take Photo of 1st Transfer Short Shot

  Media

• 2nd Transfer Position Set to?

• Fill Time at 2nd Set Transfer Position

• Take Photo of 2nd Transfer Short Shot

  Media

• 3rd Transfer Position Set to?

• Fill Time at 3rd Set Transfer Position

• Take Photo of 3rd Transfer Short Shot

  Media

• 1st Transfer Position Set to?

• Fill Time at 1st Set Transfer Position

• Take Photo of 1st Transfer Short Shot

  Media

• 2nd Transfer Position Set to?

• Fill Time at 2nd Set Transfer Position

• Take Photo of 2nd Transfer Short Shot

  Media

• 3rd Transfer Position Set to?

• Fill Time at 3rd Set Transfer Position

• Take Photo of 3rd Transfer Short Shot

  Media

• 4th Transfer Position Set to?

• Fill Time at 4th Set Transfer Position

• Take Photo of 4th Transfer Short Shot

  Media

• 1rst Transfer Position Set to?

• Fill Time at 1st Set Transfer Position

• Take Photo of 1st Transfer Short Shot

  Media

• 2nd Transfer Position Set to?

• Fill Time at 2nd Set Transfer Position

• Take Photo of 2nd Transfer Short Shot

  Media

• 3rd Transfer Position Set to?

• Fill Time at 3rd Set Transfer Position

• Take Photo of 3rd Transfer Short Shot

  Media

• 4th Transfer Position Set to?

• Fill Time at 4rth Set Transfer Position

• Take Photo of 4th Transfer Short Shot

  Media

• 5th Transfer Position Set to?

• Fill Time at 5th Set Transfer Position

• Take Photo of 5th Transfer Short Shot

  Media

• 1st Transfer Position Set to?

• Fill Time at 1st Set Transfer Position

• Take Photo of 1st Transfer Short Shot

  Media

• 2nd Transfer Position Set to?

• Fill Time at 2nd Set Transfer Position

• Take Photo of 2nd Transfer Short Shot

  Media

• 3rd Transfer Position Set to?

• Fill Time at 3rd Set Transfer Position

• Take Photo of 3rd Transfer Short Shot

  Media

• 4th Transfer Position Set to?

• Fill Time at 4th Set Transfer Position

• Take Photo of 4th Transfer Short Shot

  Media

• 5th Transfer Position Set to?

• Fill Time at 5th Set Transfer Position

• Take Photo of 5th Transfer Short Shot

  Media

• 6th Transfer Position Set to?

• Fill Time at 6th Set Transfer Position

• Take Photo of 6th Transfer Short Shot

  Media

• Observations About Short Shot Progression

• Does the Moulded Part Have Any Visually Unacceptable Knit/Weld Lines That Could Not Be Corrected?

  Yes

  No

• Are the Knit/Weld Lines in the Predicted Location From Mould Flow?

  Yes

  No

• Was Venting Improved to Correct the Issue?

  Yes

  No

• Take a Photo of the Issue and Create an Action Item

  Media

• If the Predicted Knit/Weld Line Locations Can't Be Matched, Take a Photo of the Issue and Create an Action Item

  Media

• Does the Moulded Part Have Any Gate Sink That Could Not Be Corrected?

  Yes

  No

• Is The Gate the Correct Dimensions?

  Yes

  No

• Is Cooling Sufficient in Front of the Gate?

  Yes

  No

• Take a Photo of the Gate Sink Area and Create an Action Item

  Media

• Does the Moulded Part Have Any Under Pack, Over Pack, Sinks or Readthrough That Could Not Be Corrected?

  Yes

  No

• Is The Wall Stock and Back Side Scribe Depth Correct in the Problem Area?

  Yes

  No

• Is Cooling Sufficient in the Problem Area?

  Yes

  No

• Take a Photo of the Under Pack, Over Pack, Sinks or Readthrough Area and Create an Action Item

  Media

• Does the Moulded Part Have Any Distortion, Warp, or Wavy Surfaces That Could Not Be Corrected?

  Yes

  No

• Is Cooling Sufficient in the Problem Area?

  Yes

  No

• Is There a Tooling Issue Causing the Distortion, Warp or Waviness?

  Yes

  No

• Is There a Robotic Demoulding Issue Causing the Distortion?

  Yes

  No

• Take a Photo of the Distortion, Warp, or Wavy Surface Area and Create an Action Item

  Media

• Does the Moulded Part Have Any Flow Lines or Pressure Lines That Could Not Be Corrected?

  Yes

  No

• Take a Photo of the Flow LInes or Pressure Lines and Create an Action Item

  Media

• Does the Moulded Part Have Any Blister, Bubble or Delamination Issues That Could Not Be Corrected?

  Yes

  No

• Take a Photo of the Blister, Bubble or Delamination Issue and Create an Action Item

  Media

• Does the Moulded Part Have Any Gas Marks or Air Traps That Could Not Be Corrected?

  Yes

  No

• Take a Photo of the Gas Marks or Air Traps and Create an Action Item

  Media

• Does the Moulded Part Have Any Short Shots That Could Not Be Corrected?

  Yes

  No

• Take a Photo of the Short Shots and Create an Action Item

  Media

• Does the Moulded Part Have Any Splay, Streaks, Blush Marks or Jetting That Could Not Be Corrected?

  Yes

  No

• Take a Photo of the Splay, Streaks, Blush Marks or Jetting and Create an Action Item

  Media

• Does the Moulded Part Have Any Ghosting, Blooming, or Hazing Issues That Could Not Be Corrected?

  Yes

  No

• Take a Photo of the Ghosting, Blooming, or Hazing Issue and Create an Action Item

  Media

• Does the Moulded Part Have Any Tiger Stripe Issues That Could Not Be Corrected?

  Yes

  No

• Take a Photo of the Tiger Stripe Issue and Create an Action Item

  Media

• Using the Check Fixture, Are the Moulded Parts Within Dimensional Specification?

  Yes

  No

  Check Fixture Not Available

• Take a Photo of the Dimensional Issue and Create an Action Item

  Media

Tooling Details

• Mould Length

• Mould Width

• Shut Height

• Core Weight

• Cavity Weight

• Total Weight

• End Of Arm Present and Functional at Tryout

  Yes

  No

  N/A

• Dimensional Gauge Present and Functional at Tryout

  Yes

  No

  N/A

• Identification Correct on B-side of Part (Part Number, Cavity Number, Material, Date, Shrink Scribe Lines, and Secondary Operation Locations)

  Yes

  No

• Mold Connects to Trial Press With All Intended Connectors?

  Yes

  No

• Is the Tooling Complete to All of the Customers Tooling Specifications?

  Yes

  No

• Identify What Items Do Not Match Specification

• Number of Cores

• Core #1 Location

  Core Side

  Cavity Side

• Verification

  Limit Switch

  Time

• Sequence

  Select Clamp Open Clamp Closed Ejector On the Fly During Injection During Hold

  • Clamp Open
  • Clamp Closed
  • Ejector
  • On the Fly
  • During Injection
  • During Hold

• Core #2 Location

  Core Side

  Cavity Side

• Verification

  Limit Switch

  Time

• Sequence

  Select Clamp Open Clamp Closed Ejector On the Fly During Injection During Hold

  • Clamp Open
  • Clamp Closed
  • Ejector
  • On the Fly
  • During Injection
  • During Hold

• Core #3 Location

  Core Side

  Cavity Side

• Verification

  Limit Switch

  Time

• Sequence

  Select Clamp Open Clamp Closed Ejector On the Fly During Injection During Hold

  • Clamp Open
  • Clamp Closed
  • Ejector
  • On the Fly
  • During Injection
  • During Hold

• Core #4 Location

  Core Side

  Cavity Side

• Verification

  Limit Switch

  Time

• Sequence

  Select Clamp Open Clamp Closed Ejector On the Fly During Injection During Hold

  • Clamp Open
  • Clamp Closed
  • Ejector
  • On the Fly
  • During Injection
  • During Hold

• Are All Ejectors and Cores Fitted with Limit Switches?

  Yes

  No

• Take a Photo of Which Core or Ejector Does Not Have Limit Switches and Create an Action Item

  Media

• Limit Switches Connected and Working Properly?

  Yes

  No

• Take a Photo of Which Core or Ejector Limits Are Not Working and Create an Action Item

  Media

• How Many Different Gate Styles

• Gate Style #1

  Select Edge Gate Cashew Gate Direct Drop Lifter Gate Fan Gate Pin Gate Tab Gate Sub Gate

  • Edge Gate
  • Cashew Gate
  • Direct Drop
  • Lifter Gate
  • Fan Gate
  • Pin Gate
  • Tab Gate
  • Sub Gate

• Auto Degating?

  Yes

  No

• Gate Style #2

  Select Edge Gate Cashew Gate Direct Drop Lifter Gate Fan Gate Pin Gate Tab Gate Sub Gate

  • Edge Gate
  • Cashew Gate
  • Direct Drop
  • Lifter Gate
  • Fan Gate
  • Pin Gate
  • Tab Gate
  • Sub Gate

• Auto Degating?

  Yes

  No

• Gate Style #3

  Select Edge Gate Cashew Gate Direct Drop Lifter Gate Fan Gate Pin Gate Tab Gate Sub Gate

  • Edge Gate
  • Cashew Gate
  • Direct Drop
  • Lifter Gate
  • Fan Gate
  • Pin Gate
  • Tab Gate
  • Sub Gate

• Auto Degating?

  Yes

  No

• Do All of the Drops Have the Correct Valve Gate Number Stamped on Them and They Are Easy to Read?

  Yes

  No

• Identify Which Drops Are Not Numbered or Able To Be Read

• Are the Gates and Runners the Same as Mould Flow Analysis?

  Yes

  No

  Information Not Available

• Take Photo of the Tool Sequence Plaque

  Media

• Take a Picture of the Moving Tool Half on the Operator Side.

  Media

• Take a Picture of the Fixed Tool Half on the Operator Side.

  Media

• Take a Picture of the Moving Tool Half on the Non-Operator Side.

  Media

• Take a Picture of the Fixed Tool Half on the Non-Operator Side.

  Media

• Observations About TheTool Details

Tool Spotting (Bed Out, Bluing) Report

• Use bluing ink and apply to parting and pressure pads, (if applicable). Use a thin film layer, no tissue paper, and use minimum clamp force.

• Clamp Force Used for Evaluation

• Bluing Evaluation Photos

  Media

Tool Functioning Observations

• Were There Any Overall Mould Function Issues? This Includes All Cylinders, Slides, Valve Gates, Locks, Part Counter, etc.

  Yes

  No

• Take a Photo of All Mould Function Issues and Create an Action Item

  Media

• Were There Any Tool Ejection Issues

  Yes

  No

• Take a Photo of All Issues and Create an Action Item

  Media

• If Using Cashew or Tunnel Gates, Do the Runners Eject Straight and Are Able to Pick By Robot?

  Yes

  No

  No Cashew or Tunnel Gates Used

• Which Gate Number is Not Ejecting Properly?

• Take a Photo of All Issues and Create an Action Item

  Media

• Was There Any Evidence of Galling or Burrs On Any Parting Line, or Mould Action Surfaces?

  Yes

  No

• Take Photo of All Galling Surfaces and Create Action Item

  Media

• Is the Tool Free From Any Water Leaks?

  Yes

  No

• Take a Photo of Water Leak Areas and Create an Action Item

  Media

• Is the Tool Free From Any Oil Leaks?

  Yes

  No

• Take a Photo of Water Leak Areas and Create an Action Item

  Media

Tool Related Part Quality Observations

• Does the Part Have Any Parting Line Flash?

  Yes

  No

• Take a Photo of All Flash Issues and Create an Action Item

  Media

• Does the Part Have Any Scuffing on any Surfaces From Mould Actions?

  Yes

  No

• Take a Photo of All Scuffing Issues and Create an Action Item

  Media

• Were There Any Part Ejection or Demoulding Issues Evident on Part(s)? (Include Ejector Pin or Lifter Mark Issues)

  Yes

  No

• Take a Photo of All Part Ejection or Demoulding Issues and Create an Action Item

  Media

• Does the Part Have Any Read Through from B-Side Features?

  Yes

  No

• Does the Wall Stock Ratio Match the CAD File?

  Yes

  No

• Take Photo of Problem Areas and Create Action Item

  Media

• Is the Read Through a Result of a Mould Action?

  Yes

  No

• Take Photo of Problem Areas and Create Action Item

  Media

• Take Photo of Problem Areas and Create Action Item

  Media

• Are All Part Features in Tact and Free from Distortion/Stress?

  Yes

  No

• Take a Photo of Each Feature and Area of Concern and Create Action Item

  Media

• All Part Features From OKTT, (O.K. To Tool) Data Are Present on Moulded Part?

  Yes

  No

• Confirm OKTT Data is at Current Revision. Take a Photo of Problem Area(s) and Create Action Item

  Media

• Is Venting Adequate in All Areas of Part?

  Yes

  No

• Were All Vents Opened During the Trial?

  Yes

  No

• Were There Any Difficult Areas to Vent That May Require Alternative Venting Methods?

  Yes

  No

• Take a Photo of the Difficult Area and Create Action Item.

  Media

• Take a Photo of the Difficult Area and Create Action Item.

  Media

• Is the Tool Free From Severe Abnormal Sound?

  Yes

  No

• Take a Photo of the Problem Areas and Create Action Item

  Media

Wall Stock Verification

• Measure the Wall Stock in 3 Locations and Document Measurements Here

• Location 1

• Location 2

• Location 3

Tool Temperature

• Thermal Images of the Core

  Media

• Thermal Images of the Cavity

  Media

• Tool Temperature Less Than 10 Degrees From Set Point?

  Yes

  No

• Take a Photo of the High Temperature Delta Area and Create Action Item.

  Media

Dry Cycle Verification

• Was a Dry Cycle Verification Completed?

  Yes

  No

• How Many Hours Did the Machine Run?

• How Many Cycles Were Completed?

• Dry Cycle Outcome

  Pass

  Fail

• Observations About the Dry Cycle Verification, pass/fail

• Total Parts/Sets Required To Be Made?

• Total Parts/Sets Made?

• Total Boxes To Be Shipped?

• Size of Boxes - L x W x H

• How Much Material Is Remaining (lbs)?

• General Trial Notes

• Take Photo of Trial Shop Process Sheet if Available

  Media