Molding Scrap Reduction and Reutilization

Abstract

A company named ABB, whose operations in Puerto Rico focuses on molded cable installation products, experienced scrap generation during the subassembly processes. The scrap costs represented over $200K per year. The Plant management established an objective of reducing the scrap costs by 50% and the virgin material usage by 15%. Lean Six Sigma Methodologies were used to implement a solution to capture the scrap and reutilize it in the molding process, resulting in cost avoidance of $200K per year and reduced virgin material usage by 15%. Key Terms ⎯ Effects of Granulation in Molding Process, Injection Molding, Lean Six Sigma, Plastics Engineering.