Sigma Trac # 2001616DCOP
Activity: Injection Molding Consulting
Project Title: Knit Line Reduction on Ford Ranger Rear Door
Company: XXXXXX State, Indiana
Consultants: Michael Zalipski and Kenny Presgraves
Date: July 6, 2001 – October 8, 2001
Client Contact: XXXX

Summary: Evidence of success – Consulting – improving Injection Molding Process.
Mold: G1427 - 2 cavity Rear Door Panel.
Quality Issues: Inconsistent part quality (Poor Knit line appearance)

Machine and Mold Evaluation:
Performed rigorous Machine Tests
          Hydraulic Response Test
          Injection Speed Linearity Test
          Load Sensitivity Test
          Dynamic Check Ring Test               
          Performed Rigorous Mold Tests
          In Mold Rheology Test
          Dynamic Cavity Imbalance Test
          Vent Depth Test
          Made Tooling Recommendations based on test results.
          Tool modifications consisted of:

KNITLINE PORCERAX INSERT
           EDM Back Surface of insert
           Drill and EDM ¼ inch clean out ports
           EDM face of insert