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Design of Experiments (DOE) for Plastic Packaging Manufacturing—4 days
- Workshop with process simulations to demonstrate the nature of process challenges
- How to design and analyze factorial DOEs for process optimization
- Three workshops with process simulations for practicing design and analysis of factorial DOEs
- 2-level factorial designs
- Fractional factorial designs
- Response surface methods for achieving true optimization
- Three workshops with process simulations for practicing design and analysis of factorial DOEs
Effective Statistical Process Control (SPC) for Plastic Packaging Manufacturing—4 days
- Recognizing the challenge of plastic packaging manufacture in statistical terms
- Strategy against variation in injection and blow molding processes
- How to recognize if the process changed with the help of statistics
- Intro to SPC tools including histograms, Pareto charts, scatter diagrams, DOE, and control charting
- Control charting plastic container manufacturing processes: selection, design and interpretation
- Process control tools for the special challenges of plastic packaging manufacturing
- Workshop with actual or simulated production data
- Management's role and performance measurement
Introduction to PET Container Manufacturing—3 days
- Performance Requirements, Preform and Bottle Manufacturing Processes
- Functional analysis for PET CSD, Water and Heat-set containers – flow charting the manufacturing process from resin purchase to retail sale of filled container, identification of internal and external customers and their requirements and critical container properties and manufacturing processes
- The resin drying process
- The Injection process
- One stage versus two stage injection molders, integrated versus two-step bottle manufacture
- Preform storage: the effects of handling and storage and recommended procedures
- PET preform reheating and bottle blow molding
- Special considerations for CSD, water, heat-set bottles and multilayer bottles
- Process and quality control for drying, injection and blow molding processes
- Workshops with simulations and live manufacturing process demonstrations
- Intro to statistical methods for optimizing, troubleshooting and controlling processes
- Preform and bottle design basics
PET Bottle and Preform Manufacturing Process Optimization with Special Emphasis on Stress Crack Resistance—4 days
- PET technology review
- The preform & bottle manufacturing's role in performance with special emphasis on stress cracking
- Bottle handling & distribution's role
- Designing the optimum preform & blow molding process with statistically designed experiments
- Maintaining the optimum process: Intro to control charting
- Intro to test measurement precision (repeatability and reproducibility)
- SOP's for Continuous Improvement with DOE and SPC
Effective Quality Systems for PET Preform and Bottle Manufacturing—4 days
- PET Technology review with emphasis on critical quality and process variables
- Modern quality strategy for maximum profitability for the PET preform and bottle manufacture
- Building a customer centered quality systems
- Workshops to map key processes, identify their customers and suppliers, customers' needs, the tools to fulfill them, and develop specific quality plans for each participant's needs
- Characterizing and dealing with process and quality variation
- Intro to basic statistics for quality and process control
- Intro to control charting
- Understanding and dealing with test method repeatability and reproducibility
- Modern trouble shooting techniques
- The quality department's role
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