Design of the support system for the production control of injection forming process using DFSS methodology

The urethane injection forming, process which mixes polyol and isocyanate material and makes a specific shape is the manufacturing technology which requires the chemical knowledge, the control know-how and the experience of manufacturing facilities. To analyze and control the manufacturing process of the injection forming systematically, this study introduces some DFSS (design for six sigma) tools such as process map, C&E (cause and effect) matrix, FMEA (failure mode effect analysis) and control plan. In other words, the manufacturing process is analyzed according to the following three steps: 1) making the process-map for analyzing the sequence of the manufacturing process and defining the input/output data of each process, 2) extracting the major factors affecting the product quality using C&E matrix, and 3) analyzing FEMA (failure mode effect analysis) of each process. Using the result of the analysis, this study makes the control plan and designs the detail control algorithms of the support system. Furthermore, the architecture of the support system is designed considering users' convenience and system portability.