Analysing production process influencing jar quality performance in injection of biomaterials

Abstract

Sulapac, a pioneering company in biomaterials, is committed to delivering high-quality, sustainable packaging solutions. This thesis focuses on ensuring the injection moulding processes for Sulapac’s 50 ml Premium Nordic Collection jar. Leveraging the opportunity to re-verify current processes with a new subcontractor, this study aims to ensure both the mechanical and aesthetic qualities of the product. Utilizing the Design of Experiments (DoE) methodology, key parameters such as holding pressure, cooling time, and filling speed are analysed to understand their impact on the quality and performance of the jars and lids. Additionally, Failure Mode and Effects Analysis (FMEA) is employed to identify and prioritize potential defects using the Risk Priority Number, providing actionable insights for corrective measures to elevate product quality.

The research presents a comprehensive approach, detailing step-by-step procedures for applying DoE and FMEA to rectify identified defects and streamline the manufacturing process. Findings highlight the critical importance of controlling manufacturing parameters and implementing re-verification at each step to ensure product quality consistency. The study also recommends the use of control charts for a refined monitoring of key parameters that significantly influence product quality. In addition, this systematic monitoring method enables for real-time adjustments and contributes to maintaining stability in the manufacturing process.

By understanding the interaction between key manufacturing parameters and proposing targeted improvements, this thesis equips Sulapac to meet its quality standards with their manufacturing subcontractor. The methodologies explored in this study provides a framework that can be applied to future implementation and research, contributing the Sulapac’s continuous improvement.