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Rubber & Plastic

Sector Overview

Moulding and extrusion plants face high scrap rates from surface blemishes, colour streaks, and dimensional drift. Resin prices make waste expensive.

Challenges

Defect Type Cost Driver
Surface blemishes Rework, rejection
Colour or material changeover Downtime, purging waste
Dimensional inaccuracy Warranty claims

Recommended Package

  • Six Sigma Culture – DMAIC projects focusing on PPM defect reduction.
  • Process Transformation – real-time SPC integration at presses.
  • Operational Efficiency – SMED kits for faster colour/material changes.
  • Financial Governance – part-family profitability dashboards.

Capability Building

  • Six Sigma Methodology with moulding case studies.
  • Lean Manufacturing on material flow and scrap reduction.
  • Leadership Training for shift engineers driving continuous improvement.

FAQs

Green-Belt projects typically return 5–7× their cost in material savings.
Gateway modules convert signals to OPC or MQTT for live dashboards.
Reductions of 40–60 % are common within eight weeks.
DMAIC uses designed experiments to set optimal regrind ratios.
Eliminating re-runs and purging waste lowers kWh/kg significantly.
Real-time defect reduction improves bonuses tied to first-pass yield.

Solutions

Capability Building

Industries