How to Effectively Reduce Production Costs of Precision Injection Molding
Establish a dynamic material selection mechanism: Screen cost-effective raw materials based on product precision (e.g., ±0.01mm electronic components) and mechanical requirements, avoiding overpriced special materials while meeting standards like RoHS.
Reduce waste with smart batching: Use intelligent systems to control proportioning errors within 0.5%, preventing batch scrapping. Recycle 15%-20% of crushed leftover materials after 3+ performance tests to ensure quality.
Secure favorable procurement terms: Sign long-term agreements with suppliers for tiered pricing (3%-5% discount for annual purchases over 500 tons).
Adopt modular design: Standardize common cavity structures and guide components to cut mold manufacturing costs by 10%-15%; share mold bases for same-product-line variants, replacing only cavity inserts.
Choose suitable mold materials: Use H13 hot work die steel for 1M+ annual output (500K+ cycles); opt for S50C carbon steel for small-batch trials (40% material cost reduction).
Implement regular maintenance: Conduct full inspections (polishing, lubrication) every 5,000 cycles via maintenance records, slashing unexpected repair costs by 30%.
Refine process parameters: Shorten molding cycles under tolerance constraints (e.g., reduce PC part holding time from 5s to 3.5s, boosting efficiency by 30% and cutting energy use by 15%).
Introduce automation: Deploy six-axis robots for picking, inspection, and stacking to reduce 2 operators/equipment; raise yield from 95% to 99%.
Use real-time monitoring: Apply MES systems to alarm for ±2℃+ injection molding machine temperature fluctuations, lowering defect rates from equipment issues.
Optimize equipment selection: Choose all-electric injection molding machines (30% higher upfront cost but 40% lower energy use) for <0.1mm thin-walled parts, ensuring long-term cost savings.
Conduct preventive maintenance: Change hydraulic oil and check screws every 2,000 hours to reduce unplanned downtime by 50%.
Enhance workforce efficiency: Train operators for "one person, multiple machines" (manage 2-3 devices) to lift per capita output by 50%; link piece-rate wages to quality/scrap rates via assessment systems.
Adopt digital scheduling: Adjust shifts dynamically based on orders to avoid labor idleness.
