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