Injection Moulding Tool Trial Report V4.0

• 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 #

• 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 / Project Engineer Present?

  Yes

  No

  Represented

  Virtual / Online

• Plant Program Manager / Project Engineer Name

• Plant Program Manager / Project Engineer Representative Name

• Plant Program Manager / Project Engineer 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

• Mouldflow Analyst Present?

  Yes

  No

• Mouldflow Analyst Name

• Material Supplier Present?

  Yes

  No

• Material Supplier Name

• Additional People Present at the Trial

• Observations About the Trial Facilities and Attendees

General Report Instructions

• 1. Answer all questions provided below

• 2. Add photos and notes by clicking on the appropriate icon.

  

• 3a. To add a Corrective Action, click on the paperclip icon then "Add Action", or the "Action" icon,

  

• 3b. For each action, provide a description of what needs to be done, assign to a member, set due date and priority, and click "Create Action".

  

• 4. Complete audit by clicking on "Mark As Complete", only when ALL questions have been answered.

  

• 5a. Share your report by exporting as a PDF file. The report can be shared from within the app.

  

• 5b. The report can also be shared from the desktop website as well.

  

Physical Units

• Select All Physical Units To Be Used For This Report Unless Otherwise Indicated

• 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, ADX2335, 1168X, etc)

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

• If Multiple Components are Blended, What is the Blend Ratio?

• For Blended Materials, What Equipment is Used For Blending?

  Select Gravimetric Weigh Blender Additive Auger Press Side Mixing Drum Mix By Hand/Shovel Pre-Blended By Supplier No Blending Required

  • Gravimetric Weigh Blender
  • Additive Auger
  • Press Side Mixing Drum
  • Mix By Hand/Shovel
  • Pre-Blended By Supplier
  • No Blending Required

• Multiple Colours?

  Yes

  No

• Colour Code (If Required)

• For Long Fibre Filled Materials, What is the Average Pellet Length? (mm)

• Resin Dry Time - (hrs)

• Resin Dry Temperature

• If Material is Dried (Hygroscopic), What is the Moisture Content?

• Target Shrink Rate - (mm/1000)

• Take Photo of All Material Labels

  Media

• Take Photo of the Resin for Future Reference

  Media

Machine Details

• Name of Press

• Intensification Ration - (# : 1)

• Screw Diameter - (mm)

• Barrel Size - (grams)

• Tonnage of Press (Metric Tons)

• 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

• Hot Runner Temperature

• Fill Time (Seconds)

• Volumetric Fill Speed (cm^3/sec)

• Volume % Filled Before Transfer

• Pack/Hold Time

• Pack/Hold Pressure (Plastic Pressure)

• Gate Freeze Time

• Cooling Time

• Recovery Time

• Clamp Force Used

• Maximum Injection Pressure

• Injection Pressure at Transfer

• Total Part/Shot Weight - Transfer Only / No Holding Pressure

• Total Part/Shot Weight - Fully Packed Out

• 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

• Hot Runner Temperature

• Fill Time (Seconds)

• Volumetric Fill Speed (cm^3/sec)

• Volume % Filled Before Transfer

• Pack/Hold Time

• Pack/Hold Pressure (Plastic Pressure)

• Gate Freeze Time

• Cooling Time

• Recovery Time

• Clamp Force Used

• Maximum Injection Pressure

• Injection Pressure at Transfer

• Total Part/Shot Weight - Transfer Only / No Holding Pressure

• Total Part/Shot Weight - Fully Packed Out

• 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

• Hot Runner Temperature

• Fill Time (Seconds)

• Volumetric Fill Speed (cm^3/sec)

• Volume % Filled Before Transfer

• Pack/Hold Time

• Pack/Hold Pressure (Plastic Pressure)

• Gate Freeze Time

• Cooling Time

• Recovery Time

• Clamp Force Used

• Maximum Injection Pressure

• Injection Pressure at Transfer

• Total Part/Shot Weight - Transfer Only / No Holding Pressure

• Total Part/Shot Weight - Fully Packed Out

• 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

• Hot Runner Temperature

• Fill Time (Seconds)

• Volumetric Fill Speed (cm^3/sec)

• Volume % Filled Before Transfer

• Pack/Hold Time

• Pack/Hold Pressure (Plastic Pressure)

• Gate Freeze Time

• Cooling Time

• Recovery Time

• Clamp Force Used

• Maximum Injection Pressure

• Injection Pressure at Transfer

• Total Part/Shot Weight - Transfer Only / No Holding Pressure

• Total Part/Shot Weight - Fully Packed Out

• 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

• Hot Runner Temperature

• Fill Time (Seconds)

• Volumetric Fill Speed (cm^3/sec)

• Volume % Filled Before Transfer

• Pack/Hold Time

• Pack/Hold Pressure (Plastic Pressure)

• Gate Freeze Time

• Cooling Time

• Recovery Time

• Clamp Force Used

• Maximum Injection Pressure

• Injection Pressure at Transfer

• Total Part/Shot Weight - Transfer Only / No Holding Pressure

• Total Part/Shot Weight - Fully Packed Out

• Include Picture of Reference Process Sheet

  Media

• Was a Mould Flow Completed For This Tool?

  Yes

  No

• Mould Flow Theoretical Starting Points

• Mould Flow Source

  Select Magna - Troy ESE Magna - Internal Division Bozilla Corp CAE Services FEA Mold Material Supplier Tool Source Other

  • Magna - Troy ESE
  • Magna - Internal Division
  • Bozilla Corp
  • CAE Services
  • FEA Mold
  • Material Supplier
  • Tool Source
  • Other

• Name of Mould Flow Source

• Name of Material Supplier

• Name of Tool Source

• Name of Mould flow Analyst

• 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

• Target Pack/Hold Time

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

• Target Pack/Hold Pressure (Plastic Pressure)

• Target Gate Freeze Time

• Target Cooling Time

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

• Predicted Clamp Force

• Predicted Maximum Injection Pressure

• Predicted Injection Pressure at Transfer

• Target Part/Shot Weight

• Total Shot Volume

• Valve Gate Trigger Reference Map

  Media

• Number of Valve Gate Triggers

• Valve Gate Trigger 1 (T1) Time (sec)

• Valve Gate Trigger 1 (T1) Position (mm)

• Valve Gate Trigger 2 (T2) Time (sec)

• Valve Gate Trigger 2 (T2) Position (mm)

• Valve Gate Trigger 3 (T3) Time (sec)

• Valve Gate Trigger 3 (T3) Position (mm)

• Valve Gate Trigger 4 (T4) Time (sec)

• Valve Gate Trigger 4 (T4) Position (mm)

• Valve Gate Trigger 5 (T5) Time (sec)

• Valve Gate Trigger 5 (T5) Position (mm)

• Valve Gate Trigger 6 (T6) Time (sec)

• Valve Gate Trigger 6 (T6) Position (mm)

• Valve Gate Trigger 7 (T7) Time (sec)

• Valve Gate Trigger 7 (T7) Position (mm)

• Valve Gate Trigger 8 (T8) Time (sec)

• Valve Gate Trigger 8 (T8) Position (mm)

• Valve Gate Trigger 9 (T9) Time (sec)

• Valve Gate Trigger 9 (T9) Position (mm)

• Valve Gate Trigger 10 (T10) Time (sec)

• Valve Gate Trigger 10 (T10) Position (mm)

• 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

• Hot Runner Temperature

• Fill Time (Seconds)

• Volumetric Fill Speed (cm^3/sec)

• Volume % Filled Before Transfer

• Pack/Hold Time

• Pack/Hold Pressure (Plastic Pressure)

• Gate Freeze Time

• Cooling Time

• Recovery Time

• Clamp Force Used

• Maximum Injection Pressure

• Injection Pressure at Transfer

• Total Part/Shot Weight - Transfer Only / No Holding Pressure

• Total Part/Shot Weight - Fully Packed Out

• Include Picture of Reference Process Sheet

  Media

Process Inputs

• Projected Tonnage To Be Used

• Actual Tonnage Used For Process

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

• Do All Hot Runner Zones Come Up To Temperature and Hold Temperature Within 5 Degrees?

  Yes

  No

• Which Zones Do Not Hold Temperature?

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

  Media

• Do All Hot Runner Zones Come Up To Temperature and Hold Temperature Within 5 Degrees?

  Yes

  No

• Which Zones Do Not Hold Temperature?

• Take Photo of all of the Hot Runner Screens

  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

• Number of Injection Profile Steps

• Define the Injection Speed Profile

• Explain Why More Than One Step is Needed

• Injection Speed Used

• Max Injection Pressure Setpoint

• Transfer Position

• 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

• Number of Hold Pressure Steps

• First Hold Time (sec)

• First Hold Pressure

• Second Hold Time (sec)

• Second Hold Pressure

• Third Hold Time (sec)

• Third Hold Pressure

• Fourth Hold Time (sec)

• Fourth Hold Pressure

• Fifth Hold Time (sec)

• Fifth Hold Pressure

• Sixth Hold Time (sec)

• Sixth Hold Pressure

• Seventh Hold Time (sec)

• Seventh Hold Pressure

• Eighth Hold Time (sec)

• Eighth Hold Pressure

• Ninth Hold Time (sec)

• Ninth Hold Pressure

• Tenth Hold Time (sec)

• Tenth Hold Pressure

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

Recovery Profile

• Take Photo of Recovery Profile

  Media

• Set Back Pressure

• Set Screw Speed

• Calculated Screw Surface Speed (mm/sec) - (Screw Diameter x 3.14159 x RPM / 60)

• 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

• Does the Correct Valve Gate Control Number Operate the Correct Valve Gate?

  Yes

  No

• Which Valve Gates Do Not Match the Correct Control

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)

• Calculated Residence Time (sec) - (Barrel Full Shot Stroke Available / Process Full Shot Stroke x Cycle Time)

• 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

• 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

• 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

• Is the Part Fill Balanced?

  Yes

  No

• Take a Photo of the Imbalanced Area

  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, Cold Slug, 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

• If Part Has a Blended Colour Concentrate, Does the Colour Have a Rich Appearance? (Not Streaky or Cloudy)

  Yes

  No

  N/A

• Please Provide Details

• 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

Tool Build Verification

• Is the Tool Being Verified To Meet Build / Division Standards?

  Yes

  No

• Are You Able To Inspect the Tool Before Setting, During Setting or After Removal?

  Yes

  No

• Mould To Press Clearance For Load/Unload Is Suitable?

  Yes

  No

• What Is The Locating Ring Size?

• Sprue Bushing Radius Matches Target Machine?

  Yes

  No

• Sprue Bushing Orifice Size?

  Yes

  No

• Nozzle Seat Correct

  Yes

  No

• Is there any sprue bushing damage?

  Yes

  No

• K.O. Pattern Correct for Intended Machine

  Yes

  No

• Does the Tool Hang Level or to Tooling Standards?

  Yes

  No

• Are There Enough Safety Straps and In the Correct Location?

  Yes

  No

• Hoist Rings Included and In Correct Location?

  Yes

  No

• Is the Intended Lifting Mechanism Mounted To the Tool? (Single Point Lift Or Division Standard)

  Yes

  No

• Clamp Plate Correct Size/Thickness/Holes

  Yes

  No

• Mold Painted/Correct Colour

  Yes

  No

Tool Information and Identification

• Check Off Whether the Following Items Are Located On the Tool.

• Tool Number On All Sides

• Hot Runner Manifold Schematic

• Core and Cavity Side Electrical Schematic

• Core and Cavity Side Water Schematic(s)

• Core and Cavity Side Hydraulic Schematic

• Tool I.D. Plaque

• Owner Identified On Both Tool Halves (For example, Property of FCA, STR# 12345678910, etc.)

• Document Folder or USB With Tool Information

• Name of Hot Runner Supplier

• Manifold Wiring Correct

  Yes

  No

• Wiring is Protected

  Yes

  No

• Switches Protected

  Yes

  No

• Cylinders Protected

  Yes

  No

• Main Water In/Out in Correct Location

  Yes

  No

• Spring Returns Correct

  Yes

  No

• Guide Pins Tapered

  Yes

  No

• Tool Draft is Adequate

  Yes

  No

• Surface Parting Line at Acceptable Quality

  Yes

  No

• Cavity Surface at Acceptable Quality

  Yes

  No

• Core Surface at Acceptable Quality

  Yes

  No

• Water Manifolds Correct to Standard

  Yes

  No

• Sufficient Ejector Stroke

  Yes

  No

• Type of Ejection

• Ejection Return Type

• Manifold Cross Over Present (If Applicable)

  Yes

  No

  N/A

• Do All of the Nozzle Drops Sit Flush to the Tool?

  Yes

  No

• If the Tool Has Cavity Pressure Sensors Installed, Is There the Correct Number and They Are in the Proper Locations? (Post Gate, End of Fill, and Anywhere Else Deemed Necessary by Mould Flow)

  Yes

  No

  N/A

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

• End Of Arm Grippers Have Proper Protection on Them If Standards Require It?

  Yes

  No

  N/A

• If End Of Arm Has Any Sensors On It, Do They All Work As Designed?

  Yes

  No

  N/A

• Dimensional Gauge Present and Functional at Tryout

  Yes

  No

  N/A

• Verify All of the Identification is Correct on B-side of Part On All Cavities.

• Program Name

• Customer Part Number

• Division Part Number

• Part Name

• Engineering Level

• Customer Logo

• Supplier Code

• "Property of (Customer)"

• "Made in (Country)"

• Cavity Number / "Left" or "Right"

• Mould Number

• Material

• Recycling Code

• Date Grid / Date Wheel

• Shrink Scribe Lines

• Scribe Boxes for Mould and Paint Labels

• Secondary Operation Locations

• Other (Specify)

• Take a Photo of the Identification Area for Reference

  Media

• Mould Connects to Trial Press With All Divisions' Intended Connectors? (This Includes All Hydraulic and Electrical Connectors for Cores, Ejectors, Valve Gates, Water, Limit Switches, Hot Runners, Mechanical Ejectors, etc.)

  Yes

  No

• Is the Tooling Complete to All of the Divisions Tooling Specifications? (This Includes the Correct Gender and Colour For Each Water, Core, Ejector and Valve Gate Connector)

  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

• Is the Gate Vestige Acceptable?

  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

• Is the Gate Vestige Acceptable?

  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

• Is the Gate Vestige Acceptable?

  Yes

  No

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

  Yes

  No

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

• Do the Numbers Match the Manifold Drawing?

  Yes

  No

  N/A

• Do the Numbers Match the Manifold Drawing?

  Yes

  No

• Are the Gates and Runners the Same as the Mould Flow Analysis and/or the Tool Design Standard?

  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 The Tool Details

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 Issues with the Tool Ejection Function?

  Yes

  No

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

  Media

• Do All Lifters Sit Flush and Fit Well?

  Yes

  No

  N/A

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

  Media

• Is The Part Presented in a Manner That Can Be Picked By a Robot?

  Yes

  No

  No Robot Intended

• 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

• If Using Valve Gates, Do All of the Valve Pins Seal Off Clean in the Tips?

  Yes

  No

  No Valve Gates Used

• Which Valve Gate Number(s) are Not Sealing 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, Slides, Pins, Cores, Bushings 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 Scratches, Nicks, or 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 Part Damage, Parts Sticking, Scuffing, Scratches or Ejector Pin / 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

• All Part Features, Including Tabs, Bosses and Tethers Are 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, With Clear Channels to Atmosphere, and Match Standards?

  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

• Is There Venting To Atmosphere Holes In Closed Areas?

  Yes

  No

• All Lifters Are Vented To Standards?

  Yes

  No

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

  Media

• Is There Venting To Atmosphere Holes In Closed Areas?

  Yes

  No

• All Lifters Are Vented To Standards?

  Yes

  No

• Is There Venting To Atmosphere Holes In Closed Areas?

  Yes

  No

• All Lifters Are Vented To Standards?

  Yes

  No

• Is There Venting To Atmosphere Holes In Closed Areas?

  Yes

  No

• All Lifters Are Vented To Standards?

  Yes

  No

• Is the Tool Free From Severe Abnormal Sound?

  Yes

  No

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

  Media

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

Tool Spotting (Bed Out, Bluing).

• Was the Tool Spotting Verification Completed?

  Yes

  No

• 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

• Are Pressure Pads Set Up and Functioning Properly?

  Yes

  No

  N/A

Wall Stock Verification

• Was a Wall Stock Verification Completed?

  Yes

  No

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

• Location 1

• Location 2

• Location 3

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

Opti-Check Verification

• Does the Tool Have Opti-Check Sensors for Tool Movement Monitoring?

  Yes

  No

• Clamp Tonnage Used

• Number of Opti-Check Sensors Used

• Sensor #1 Location

• Opti-Check Sensor Reading

• Photo of Sensor Graph

  Media

• Is There Feather Flash Present in Area of Sensor?

  Yes

  No

• Take Photo of Feather Flash in the Area of the Sensor

  Media

• Sensor #2 Location

• Opti-Check Sensor Reading

• Photo of Sensor Graph

  Media

• Is There Feather Flash Present in Area of Sensor?

  Yes

  No

• Take Photo of Feather Flash in the Area of the Sensor

  Media

• Sensor #3 Location

• Opti-Check Sensor Reading

• Photo of Sensor Graph

  Media

• Is There Feather Flash Present in Area of Sensor?

  Yes

  No

• Take Photo of Feather Flash in the Area of the Sensor

  Media

• Sensor #4 Location

• Opti-Check Sensor Reading

• Photo of Sensor Graph

  Media

• Is There Feather Flash Present in Area of Sensor?

  Yes

  No

• Take Photo of Feather Flash in the Area of the Sensor

  Media

• Sensor #5 Location

• Opti-Check Sensor Reading

• Photo of Sensor Graph

  Media

• Is There Feather Flash Present in Area of Sensor?

  Yes

  No

• Take Photo of Feather Flash in the Area of the Sensor

  Media

• Sensor #6 Location

• Opti-Check Sensor Reading

• Photo of Sensor Graph

  Media

• Is There Feather Flash Present in Area of Sensor?

  Yes

  No

• Take Photo of Feather Flash in the Area of the Sensor

  Media

• Total Parts/Sets Required To Be Made?

• Total Parts/Sets Made?

• Two Parts Saved As Tooling Samples?

  Yes

  No

• Total Boxes To Be Shipped?

• Size of Boxes - L x W x H

• Packaging Acceptable to Protect Parts During Shipping?

  Yes

  No

• How Much Material Is Remaining (lbs)?

• Marked Up Sample Parts Saved So They Can Be Sent With the Tool?

  Yes

  No

• General Trial Notes

• Take Photo of Trial Shop Process Sheet if Available

  Media