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Injection Molding Maintenance Technician Package
Injection Molding Maintenance Technician Package
List Price: $2,767.00
Our Price: $1,297.00
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Product Code: IM_302_US

Injection Molding Maintenance Technician Package

This online training package is a great way to teach your maintenance and processing personnel more about advanced maintenance. A good understanding of machine hydraulics is critical to becoming a great processor: it's difficult to troubleshoot instabilities unless you know how the machine manages the hydraulic fluid. Proper injection mold and molding machine maintenance techniques are covered along with the 5S System.

26 Online Courses & Worksheets (26-50 hours + Study Guides + Worksheet)

Package Course Descriptions:

Injection Molding Basics

Our Basics series provides participants with a general understanding of the three major aspects of injection molding; the injection molding machine, the molding process, and the injection mold. These programs use 3D animation to demonstrate the inner workings of the machine and mold and to easily convey otherwise complex concepts. Important safety precautions are stressed throughout these training programs.

These basic injection molding training programs are ideal for new hires, yet also serve as an excellent refresher course for any employee involved in plastics processing; from operators and technicians to management and setup personnel.

Part 1: Machine

- Cites important safety precautions for working around injection molding machines
- Gives an introduction to the injection molding process
- Introduces machine types and the different modes of operation
- Discusses injection molding machine components and their respective functions
- General procedures for starting up and shutting down a molding machine

Part 2: Process

- Discusses polymers and the three criteria used to classify them
- Covers some of the more common procedures for material preparation
- Introduces the three phases of the molding process; injection, cooling and ejection
- Explains the need for maintaining an accurate process log
- Defines common injection molded part defects and explains their causes

Part 3: Mold

- Explains the specific functions that an injection mold must perform
- Introduces the various machining methods used to construct an injection mold
- Discusses the three mold configurations used in the industry
- Covers common runner shapes and gate types used in injection molds
- Gives an overview of proper injection mold maintenance

3 Online Courses (3-6 hours + Study Guides)

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

3 Online Courses (3-6 hours + Study Guides)

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

2 Online Courses (1-3 hours + Study Guides)

Math for Scientific 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

2 Online Courses (3-4 hours + Study Guides)

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

2 Online Course (2-4 hours + Study Guides)

Injection Mold Maintenance

This program details procedures for proper mold care before, during, and after a production run - stressing important safety considerations for mold handling. From mold storage to part removal, this course provides participants with good mold maintenance habits and aims to extend tool life and increase its productivity.

- Proper mold maintenance
- Mold storage and preparation
- Water line maintenance
- Techniques for extending tool life

1 Online Course (1-2 hours + Study Guide)

Injection Molding Machine Maintenance

This online course is designed to introduce the many maintenance considerations for an injection molding machine. Participants are also shown newer technologies; such as laser leveling, ultrasonic tie bar stretch measuring, and portable machine process monitors.

- Basic machine maintenance and safety concerns
- Fluid maintenance
- Platen maintenance
- Screw and barrel maintenance
- Preventative maintenance and logging

1 Online Course (1-2 hours + Study Guide)

Injection Molding Hydraulics

These online training courses demonstrate the importance of hydraulics – and the proper maintenance of hydraulic components – in the injection molding process. Machine operators will learn ways to reduce wear on hydraulic components, while more advanced employees concentrate on hydraulic print reading and theory.

- Basic hydraulic theory
- The role of hydraulics in injection molding
- The function and purpose of hydraulic components
- Recognition of hydraulic symbols
- Directional valves and flow controls
- Hydraulic pumps and motors
- Proportional valves and servo valves
- Hydraulic fluid management

2 Online Courses (2-4 hours + Study Guides)

Process Control Systems

This training program details process control systems and is designed to help molders make more educated choices. Process Control Systems is a must for any facility which employs (or plans to employ) closed loop process control.

Open loop vs. closed loop process control
How process control reduces variation
Closed loop controllers
Proper use of process control

1 Online Course (1-2 hours + Study Guide)

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.

5 Online Courses + Worksheets (3-6 hours)

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

4 Online Courses & Worksheet (3-6 hours + Study Guides & Worksheet)

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