Specifically focused on injection molding, the online courses in this training package provide participants with the necessary information to prepare for the Level 1 Certification Exam, which is also included.
package includes:
- Introduction to Injection Molding
This course provides participants with a general introduction to the plastics industry. The primary focus of this training program is the day-to-day operations of a typical injection molding facility.
An Introduction to Injection Molding was created for newcomers to the injection molding industry or anyone that would like to learn more about plastics. We recommend that new hires take this course before participating in our Injection Molding Basics series.
- An overview of plastics and the industry
- A typical molding facility
- General plant safety
- An introduction to the molding process
- Molding machine components
- Material handling
- Injection mold terminology
- Common part defects
- Injection Molding Basics
Our Basics series provides participants with a general understanding of the three major aspects of injection molding; the injection molding machine, the molding process, and the injection mold. These programs use 3D animation to demonstrate the inner workings of the machine and mold and to easily convey otherwise complex concepts. Important safety precautions are stressed throughout these training programs.
These basic injection molding training programs are ideal for new hires, yet also serve as an excellent refresher course for any employee involved in plastics processing; from operators and technicians to management and setup personnel.
Part 1: Machine
- Cites important safety precautions for working around injection molding machines
- Gives an introduction to the injection molding process
- Introduces machine types and the different modes of operation
- Discusses injection molding machine components and their respective functions
- General procedures for starting up and shutting down a molding machine
Part 2: Process
- Discusses polymers and the three criteria used to classify them
- Covers some of the more common procedures for material preparation
- Introduces the three phases of the molding process; injection, cooling and ejection
- Explains the need for maintaining an accurate process log
- Defines common injection molded part defects and explains their causes
Part 3: Mold
- Explains the specific functions that an injection mold must perform
- Introduces the various machining methods used to construct an injection mold
- Discusses the three mold configurations used in the industry
- Covers common runner shapes and gate types used in injection molds
- Gives an overview of proper injection mold maintenance
- Understanding Plastics
This program explains how and why plastics are different and cites several different types of polymers and processing considerations. Understanding Plastics emphasizes material handling, explains regrind, and covers the effects that moisture can have on molded part properties during processing.
- The definition of plastics
- Polymer classification
- Material properties affected by processing
- Proper material handling techniques
- Processing characteristics of virgin and regrind
- Establishing a Scientific Molding Process
This scientific molding training course provides participants with in-depth processing information to better prepare them for making appropriate and cost-effective decisions when establishing or improving a scientific injection molding process.
The course teaches a processing strategy that properly decouples 1st stage fill from 2nd stage pack. Students who understand and utilize the strategy described in this course will produce processes with a much higher repeatability. The steps outlined in this course are intended to quickly establish a scientific injection molding process, reduce downtime and improve process efficiency.
- General Rules for Scientific Processing
- Scientific Process Optimization Strategies:
- 1st Stage Filling
- 1st Stage to 2nd Stage Transfer
- 2nd Stage Pack
- Screw Delay
- Screw Recovery
- Screw Decompression
- Cooling Time
- Mold Opening
- Part Ejection
- Mold Closing
- Clamping
- Processing Parameters for Scientific Molding
This 3-part training program will provide participants with a better understanding of the parameters involved with a scientific injection molding process and the control panels of injection molding machines.
This course is beneficial to die setters, process technicians, maintenance personnel, engineers, and anyone else using the control panel.
Part 1 - Introduction
- Scientific Molding Overview
- 5 General Rules for Scientific Molding
- Understanding the Process Controller
- Common Units for Process Parameters
Part 2 - Process
- Process Inputs versus Process Outputs
- 1st Stage Injection Inputs and Outputs
- 2nd Stage Packing Inputs and Outputs
- Cooling Inputs and Outputs
- Screw Recovery Inputs and Outputs
- Other Commonly Found Process Input
- Material Drying Technology
Routsis Training’s two Material Drying Technology online courses provide participants with a better understanding of how different polymers are best dried and prepared for reliable processing. These courses show participants how proper plastics material handling and drying is critical to produce a consistent product and process. Course One reviews polymer basics, as well as both hygroscopic and non-hygroscopic polymers – to better convey the importance of properly drying water-sensitive materials.
Material Drying Technology, Course 1
- Polymer Basics
- Hygroscopic vs. Non-Hygroscopic Polymers
- Hydrolysis
- Purposes of Drying
- Dewpoint
- Dewpoint Measurement
- Dewpoint Sensors
- Drying Procedures
Material Drying Technology, Course 2
- Hot Air Dryers
- Compressed Air Dryers
- Desiccant Dryers
- Vacuum Dyers
- Calculating Material Consumption
- Calculating Residence Time
- Calculating Dryer Capacity
- Electric Injection Molding
Our two Electric Injection Molding courses will provide participants with a better understanding of the benefits and capabilities of modern all-electric injection molding machines. Safety concerns particular to electric molding machines are also covered.
1: Understanding Electric Injection Molding Machines
This training program will provide participants with a better understanding of how electric injection molding machines function – as well as the many benefits and capabilities associated with electric molding machines.
- General Injection Molding Safety
- Electric Molding Machine Safety
- Machine Guarding
- Comparing Hydraulic and Electric Machines
- Basic Molding Machine Functions
- Efficiency, Accuracy and Repeatability
- Alternative Machine Designs
- Typical Uses for Electric Injection Molding Machines
2: Processing with Electric Injection Molding Machines
Packed with in-depth processing information, this course will undoubtedly prepare processors for making more appropriate and cost-effective decisions. Participants will also learn how to optimize any process that’s running on an electric injection molding machine.
- Closed-Loop Process Controls
- Hydraulic vs. Electric Molding Machine Controls
- Process Optimization Strategies:
- 1st Stage Filling
- 1st Stage to 2nd Stage Transfer
- 2nd Stage Pack
- Screw Delay
- Screw Recovery
- Screw Decompression
- Cooling Time
- Mold Opening
- Part Ejection
- Mold Closing
- Clamping
- Math for Molders
This two-part training program was created for all personnel within the injection molding industry who would like to expand or fine-tune their math skills.
These courses will greatly benefit any participant of RJG’s classroom-based Master Molder SM Certification Series either as a primer or as follow-up training.
Part 1
- Whole Numbers, Negative Numbers and Decimals
- Using a Calculator
- Addition, Subtraction, Multiplication and Division
- Rounding Numbers and Significant Figures
- Formulas, Equations and Order of Operations
Part 2
- Metric and Imperial Units
- Length and Distance
- Area, Volume & Flow
- Weight, Mass and Force
- Conversions
- Understanding Percentages
- Calculating Plastic Pressure and Part Shrinkage
- Calculating Tolerances
- Scientific Troubleshooting for Injection Molders
These four in-depth scientific molding training programs provide participants with the knowledge base required to identify and troubleshoot over twenty-five of the most common injection molded part defects. Users will also come away with a better understanding of how to best process, document and maintain a reliable scientific injection molding process.
Introduction
This scientific molding training program focuses on the 7-step process to scientific troubleshooting. Participants are also presented with information and practices on how to best process, document and maintain a reliable scientific injection molding process.
- Step 1 – Develop a Scientific Molding Process
- Step 2 – Properly Document the Process Outputs
- Step 3 – Examine the Defective Part and Rule Out Obvious Causes
- Step 4 – Compare the Current Process with the Documented Process
- Step 5 – Return the Process to the Documented Standard
- Step 6 – Verify the Part and Process
- Step 7 – Document all Changes Made
Visual Defects
Nine of the most common visual defects encountered in injection molding processing are covered within this extensive scientific molding training program. Participants will be better prepared to troubleshoot these defects as each one will be defined and their respective causes and corrections will be explained in detail. Defects include:
- Flash
- Sinks and Voids
- Short Shots
- Jetting
- Gate Blush
- Burning
- Flow Lines
- Weld and Meld Lines
- Poor Surface Finish
Dimensional Defects
This scientific injection molding training program will provide participants with a better understanding of how to best troubleshoot five (5) of the most common dimensional defects encountered in injection molding. Each defect will be defined and their respective causes and corrections will be explained in detail. These dimensional defects include:
- Large Parts
- Small Parts
- Larger Parts at the Gate
- Smaller Parts at the Gate
- Warpage
Material and Cycle-Related Defects
After completing this scientific molding training program, participants will have a better understanding of how to best identify and troubleshoot many of the most common Material and Cycle-Related defects encountered in injection molding. Each defect will be defined and their respective causes and corrections will be explained in detail. The material and cycle-related defects discussed in this course include:
- Splay, Bubbles, and Blisters
- Brittleness, Cracking, and Crazing
- Delamination
- Contamination
- Poor Color Distribution
- Part Sticking and Ejector Pin Marks
- Occasional Part Hang-Up
- Injection Mold Maintenance
This program details procedures for proper mold care before, during, and after a production run - stressing important safety considerations for mold handling. From mold storage to part removal, this course provides participants with good mold maintenance habits and aims to extend tool life and increase its productivity.
- Proper mold maintenance
- Mold storage and preparation
- Water line maintenance
- Techniques for extending tool life
- The 5S System
5S is a critical component of Lean Manufacturing. The 5S system is used by successful manufacturing facilities worldwide. It consists of 5 simple and concise steps – Sorting, Straightening, Sweeping, Standardizing, and Sustaining – that can help your facility reduce clutter and waste and, ultimately, increase efficiency and productivity.
Production SkillSet™
Our online 5S training courses are built on Routsis Training’s exclusive SkillSet™ model. These courses combine clear online training videos and hands-on worksheets. This approach allows companies to perform the same type of classroom learning found in popular seminars in the comfort of their own production environment.
Each unique training course is a blend of the following components:
- BACKGROUND:
Your technicians understand the goal of each Production SkillSet™ - PURPOSE:
Technicians learn specifically how each Production SkillSet™ applies to their job - EQUIPMENT:
Items are detailed to ensure techs have the tools they need to succeed - PROCEDURE:
Each step is demonstrated so your techs can proceed with confidence - WORKSHEET:
Contains all the information your techs need to succeed with each SkillSet™
Step 1: Sorting
In the 5S System, the Sorting step’s goal is to eliminate all unnecessary items from the immediate workplace. This is done by sorting the workplace to determine what to keep, what to toss, and what to store. This helps prevent clutter from interfering with everyday production activities.
Step 2: Straightening
At the end of the Straightening step, everything in the workplace is neatly organized; resulting in a more convenient and more efficient workplace.
Step 3: Sweeping
In the Sweeping step, the best method for cleaning each selected area in the workplace is determined. A reasonable cleaning schedule should also be determined to ensure the workplace remains efficient, clean and organized.
Step 4: Standardizing
The goal of the Standardizing step is to achieve consistency. A similar appearance and layout should be applied to all workstations whenever possible. This step is often performed after a similar workplace or area within the plant has already been straightened.
Step 5: Sustaining
The purpose of the Sustaining step is maintenance. This is achieved by a review of the workplace and the existing Sorting and Straightening documentation – to ensure the workplace is efficient and up-to-date. This helps identify necessary materials or equipment that have been added to the workplace but have not yet been incorporated into the 5S documentation.
- BACKGROUND:
- Level 1 : Injection Molding Professional Certification Exam
Routsis Training’s globally recognized Professional Certification demonstrates a broad-spectrum understanding of the injection molding industry.
In order to attain certification, candidates must have a working knowledge of injection molding safety, machinery, processing, tooling, materials, and quality — and demonstrate a solid understanding of current industry best practices.
Who Should Consider Certification:
From machine operators to engineers to plant managers, anyone working in the injection molding industry should consider Level 1 Certification for Injection Molding Professionals. For individuals, this certification can help advance their careers and industry standing. Companies should strongly consider offering this certification exam to their employees. A certified workforce gives managers confidence that their team will be able to rise to the challenges of a modern manufacturing environment.
How to Get Certified:
Our Level 1 exam is conducted entirely online. This comprehensive test takes approximately 1.5 hours to complete — with a time limit of 3 hours. Upon completion of the exam, participants are immediately notified whether they’ve passed or not, via email.
Those who attain a passing score will receive their certificate. Those who do not pass receive a detailed report indicating areas in which further improvement is needed.
How the Exam is Structured:
The Level 1 test consists of multiple categories and various types of questions:
A series of True/False questions are used to cover a wide range of topics. The exam also uses multiple choice questions to provide stronger indication of the candidate’s understanding of common injection molding concepts. Finally, scenario-solving questions are used to gauge the participant’s working knowledge of injection molding.
The questions in our Level 1 exam cover critical concepts and are divided into the following categories:
- Injection Molding Safety
- Basic 5S & Housekeeping
- General Molding Process
- Injection Mold Basics
- Molding Machinery Basics
- Plastics Material Basics
- Basic Scientific Molding
- Defect Troubleshooting
- Basic Quality & Mathematics
How to Prepare for Level 1 Certification:
Although preparation training is not necessary to achieve certification, participation in Routsis’s structured Injection Molding training programs can greatly increase a candidate’s chances of successfully completing the examination. Most of our corporate customers use Routsis Training’s exclusive RightStart™ in-house employee development system. For individuals and small companies, we offer an online training package specifically geared toward preparing for and attaining Level 1 certification.
