Housekeeping as a source of scrap reduction

Ever walk onto a molding floor and notice it is almost as clean as an operating room in a hospital?  Most of us have been through facilities like this.  But many of us can’t, won’t, or don’t think we can afford to make the molding shop looking like it could pass an FDA inspection.  There are many of my client’s facilities where grease ruined dress slacks, shirt, and tie are the cost of doing business.  But with identical equipment the scanky and clean shops will show a discernable difference in productivity.

Black specks and other contamination is a definable source of scrap for you and is easily fixed:

Grinders and vacuum loaders work on the simple principle of creating a vacuum from the outside air and pulling the pellets up the same way leaves blow around in a breeze.  If the air in the system is full of dust etc. you’ll get it neatly loaded into the machine and molded into parts as black specs.  Plastic pellets are highly static sensitive.  With a high static charge an open hopper, a Gaylord, or bag will suck the dust out of the air and it will cling to the pellet.

Changing the mentality of folks to NOT create a dust storm in the plant is hard.  First remove any compressed air hose with a blow-off fitting.  Compressed air might be used to activate cylinders or air blow offs in the mold but they shouldn’t be blowing dust around.  Make sure the wand on your vacuum loader is NEVER placed on the floor.  If it does, it will simply suck all the dust from the floor into the machine.  Cover the Gaylords with these plastic covers that have a sock that will accept the wand.  If loading out of a bag, make sure it is taped closed when you are done.

Fix the leaks – the cat litter used to soak up oil gives off an awful lot of dust.  If anyone has ever ‘dropped’ a mold onto a skid next to a machine you can actually see the snowstorm of dust coming down from the overhead beams because the building shook.  Buy a hepa-vacuum to clean up.  DO NOT use a shop vacuum because they blow out fine particles of dust when in use.  Mopping with detergent then rinsing with water not only picks up the grease but also picks up the dust on the floor.

Cool your facility but make sure the shop has a slightly positive pressure.  This will keep the outside air from blowing into the molding facility.

Calculate the cost of what you’re loosing.  Implement some basic training and maintenance.  Even if you purchase some of the stuff mentioned above you’ll see a dramatic improvement in your profits.  Think about it.
 

Contact me with questions put in the subject line QUESTIONS.
Bill Tobin, WJT Associates, E-mail: bill4012@hotmail.com