ABC SDN.
BHD
SOP
Plastic Injection Molding Operation
Revision History
CRF.
Rev. No. Para.
No.
0 - All
Prepared by
Prepared by
Name
Signature
Date 1/1/2023
NOTE: The details of change shall be documented in the CHANGE REQUEST FORM (CRF).
Doc. No: WI-001
Rev. No: 0
Eff. Date: 1/1/2023
Page No: Page 1 of 2
Description of Change Eff. Date
New Release 1/1/2023
Reviewed &
Approved By
1/1/2023
in the CHANGE REQUEST FORM (CRF).
WORK INSTRUCTION (WI)
Title: Plastic Injection Molding Operation
WI Number: WI-001
Department: Production
Prepared by: [Name]
Date: [Date]
Version: 1.0
1. Purpose
This Work Instruction provides a step-by-step guide to operate the plastic injection molding mach
2. Tools and Equipment Required
Plastic Injection Molding Machine (Model: [Model No.])
Mold for specified parts
Hopper for plastic resin loading
Safety Equipment (Gloves, Safety Glasses, etc.)
Tool kit (for mold installation)
Quality control instruments (Calipers, Micrometer)
3. Procedure Steps
3.1 Machine Setup
1. Prepare Work Area
Sample PICTURE
Ensure the work area is clean and free from clutter.
Check that the emergency stop button is functional.
2. Install the Mold
Sample PICTURE
Select the appropriate mold for the part based on the production order.
Perform a visual inspection for damage or wear.
Install the mold into the machine using the appropriate tools, ensuring it is aligned and secur
3. Load the Plastic Resin
Sample PICTURE
Confirm the type and color of plastic resin specified in the production sheet.
Fill the hopper with the correct resin and close the hopper lid to prevent contamination.
4. Set Machine Parameters
Sample PICTURE
Using the control panel, enter the required parameters:
Temperature: [Specify]
Injection Pressure: [Specify]
Cycle Time: [Specify]
Allow the machine to reach the correct operating temperature before starting.
3.2 Machine Operation
1. Start the Injection Molding Cycle
Sample PICTURE
Press the start button to initiate the injection process.
Monitor the first cycle to ensure proper injection and ejection of the part.
2. Monitor the Production Process
Sample PICTURE
Continuously monitor the machine's performance during operation:
Check the display for any alarms or issues.
Ensure the part is ejected correctly, without damage.
Adjust the settings if the cycle time or part quality is inconsistent.
3. Inspect the First Parts
Sample PICTURE
After the first few parts are ejected, inspect them for:
Dimensions: Use calipers or micrometers to ensure dimensional accuracy.
Surface Finish: Check for any defects such as bubbles, warping, or sink marks.
Document the initial inspection results in the Production Logbook.
3.3 Quality Control
1. Regular Quality Inspections
Sample PICTURE
Every 30 minutes or after 50 cycles, inspect the parts for consistency using the quality contro
Record the measurements in the Quality Control Log.
2. Handling Defective Parts
Sample PICTURE
If defective parts are found (e.g., incorrect dimensions, poor surface quality), immediately ad
Set aside defective parts for rework or disposal as per company policy.
Inform the supervisor of any issues that persist after adjustments.
3.4 Machine Shutdown
1. End of Production Run
Sample PICTURE
At the end of the shift or production order, stop the machine by pressing the shutdown butto
2. Mold Removal
Sample PICTURE
After the machine has cooled, carefully remove the mold and clean it using a soft cloth.
Store the mold in the designated area to prevent damage.
3. Clean the Machine
Sample PICTURE
Clean the machine and surrounding area to ensure there is no leftover material or debris.
Perform routine checks on the machine and document any maintenance needs in the Mainte
4. Safety Precautions
Always wear Personal Protective Equipment (PPE), including gloves, safety glasses, and h
Keep hands and tools away from the mold area during operation.
Make sure the emergency stop buttons are functional before starting the machine.
Never attempt to manually remove parts while the machine is in operation.
5. Records to Maintain
Production Logbook: Record the number of parts produced, cycle time, and any adjustments
Quality Control Log: Document the results of part inspections.
Maintenance Log: Record any machine malfunctions or maintenance performed during the s
6. Visual Aids
Here is a visual representation of the machine operation setup:
Label A: Hopper for Resin
Label B: Mold Setup
Label C: Machine Control Panel
Label D: Part Ejection Area
Sample PICTURE
7. Document Control
Document Version: 1.0
Last Updated: [Date]
Next Review Date: [Date]
ection molding machine for consistent and high-quality production of plastic parts.
is aligned and secured.
contamination.
nk marks.
ng the quality control checklist.
ity), immediately adjust the machine settings.
the shutdown button and turning off the power supply.
ng a soft cloth.
aterial or debris.
needs in the Maintenance Log.
afety glasses, and heat-resistant clothing.
and any adjustments made during the operation.
formed during the shift.
