Approximately twice per quarter

This 10-day certificate course focuses on the best practices of process development, documentation, and duplication that should be used on any mold in any machine in any location to support the Lean Six Sigma initiatives. This is not necessarily so you can “run machines” but is the best way to achieve the required level of understanding for all those involved in the tasks or the management of injection molding. How to build the best process in the least amount of time, and evaluate the process and processor. Each day involves some participative classroom time, daily quizzes, and hands-on time with the molds and machines. There are 10 hours of final exams during the last 2 days to confirm the effective transfer of the critical knowledge and skills of Part Design, Molds, Materials, Equipment, and DeCoupledSM 2 Processing. A good understanding of shop math is required.

Pricing (includes books, tests, breakfast, and lunch each day):
Jabil employee: $3,778
Non-Jabil employee: $4,445 (this includes customers and key partners, but not competitors).

Approximately once per quarter

This 10-day certificate course focuses on the use of cavity pressure to reduce the effect of normal variation on the parts caused by the material. This is truly a Lean Six Sigma molding. Each day involves some participative classroom time, daily quizzes, and time hands-on time with the molds and machines. The lab time allows you to experience the improved process control cavity pressure can provide first hand as well as some standard procedures for molding machine evaluations. There are 10 hours of final exams during the last 2 days to confirm the effective transfer of the critical knowledge and skills of Part Design, Molds, Materials, Equipment, and DeCoupledSM 3 Processing. Master Molder 1 certificate is required.

Pricing (includes books, tests, breakfast, and lunch each day):
Jabil employee: $4,118
Non-Jabil employee: $4,845 (this includes customers and key partners, but not competitors).

Approximately twice per quarter

This workshop is designed to provide participants with valuable hands-on machine time to reinforce the methodologies they learned in Injection Molding Essentials. It offers the same excercises as Master Molder I, but with half the practice time and none of the testing.

Attendees will acquire the knowledge they need to dissect and rebuild the process using data driven methodologies, then document the return on investment and indicate potential improvement areas using the current condition of the machine and mold. The end result will be the most robust process possible with the current conditions.

Course Highlights

• Machine Qualification Tests
  • Load Sensitivity
  • Pressure Response
  • Injection Speed Linearity
  • Dynamic Check Ring Repeatability Test
  • Clamp/Mold Deflection Study
• Mold Performance requirements and weakness identification
  • Pressure Loss test
  • Perform a gate seal study to determine optimal hold time
  • Identify the cavity balance at all injection speeds
  • Create a temperature map of the mold
• Validate machine and mold capabilities
• Build and document a robust Decoupled procee with the current machine and mold conditions

Pricing (includes books, tests, and lunch each day):
Jabil employee: $1,866
Non-Jabil employee: $2,195 (this includes customers and key partners, but not competitors).

Approximately twice per year

This 3-day course includes working in teams to actually build a DeCoupled process, design the experiment (the right way), run the samples, measure the parts, enter the data into Minitab, and review the results.

The injection molding process does not comply well with the standard DOE type rules very well at all. For example, randomizing the trials is not practical whenever temperatures are used as a factor. Also changing one parameter/factor on the injection molding machine affects many things and can violate our fundamental processing rules. Everything becomes an interaction.

Most often people use a DOE type study to find what parameters to use to “make the right size part”. Often this results in a “bad” process that does not comply with the DeCoupled Molding rules and is not as stable. DOE should not be used to develop a process. It should only be used on a fully capable process and never sacrificing the Six Sigma (DeCoupled) methodology.

There are two ideal ways to qualify for the course, but exceptions have been made.

1. You are a certified Master Molder 1 with some DOE and Minitab experience.
2. You are a certified Black Belt and have passed an RJG DeCoupled Molding course such as; Systematic Molding, Systematic Molding for Tooling Engineers, Strategies for Successful New Tool Transfers, or Master Molder 1.

Pricing (includes books, tests, breakfast, and lunch each day):
Jabil employee: $2,214
Non-Jabil employee: $2,605 (this includes customers and key partners, but not competitors).

Systematic Molding is a three-day foundational course for anyone who wants to develop a systematic approach to molding. Through a combination of classroom instruction and activity-driven learning, students leave with a better understanding of how to develop a machine-independent process, how to make data-driven improvements to existing processes, and how to effectively troubleshoot using scientific and systematic approaches.

Students will also understand the cause and effect relationships between the machine, process, mold, and material as well as how and why polymer behavior is influenced. This will allow them to make informed decisions for lasting solutions instead of band-aid fixes to the process.

This course is a great way to help students be successful in Master Molder!

Course Highlights

• Mold and part design considerations
• The four plastic variables of injection molding
• The molding system
• The molding problem simply stated
• Process control from the plastic’s point of view
• Introduction to instrumentation strategies

Pricing (includes books, tests, breakfast, and lunch each day):
Jabil employee: $1,866
Non-Jabil employee: $2,195 (this includes customers and key partners, but not competitors).

This 2-day course is designed for anyone new to injection molding. It provides a solid foundation for understanding the injection molding process and the critical practice of good production techniques. Participants will fully grasp the elements and variables involved in the injection molding process and learn key terminology that will help them communicate and solve molding problems.

Students leave this course familiar with all major components of an injection molding machine and mold, as well as the three elements of the cycle and what happens during each phase. They will understand the general nature and properties of plastics, the economic impact of making rejects, blocking cavities, and cycle time variation, and the importance of the plastic variables (melt temperature, flow rate, pressure gradient, cooling rate, and time) when troubleshooting a process.

Course Highlights

• Nature and properties of plastics
• Basic injection molding
• The clamp, injection unit, and mold
• Elements of the cycle
• Molding for quality
• Avoiding common molding problems

Pricing (includes books, tests, and lunch each day):
Jabil employee: $1,284
Non-Jabil employee: $1,511 (this includes customers and key partners, but not competitors).

This 4-day course provides molders, toolmakers, and design engineers with a common language and the universal knowledge required to successfully design and produce plastic injection molded components. Improving general knowledge of the steps required for part design reduces the risk of less than optimum tooling conditions, therefore minimizing exposure to injection molding non-conformities that do not meet the quality requirements of the customer.

Class topics address good manufacturing processes (GMP) for plastic part design, fundamental material characteristics, basic tooling concepts, necessary processing characteristics, molding non-conformities, and tolerances. The course also discusses how part design and material selection affect the cost of tooling and piece price. During training, we utilize industry examples as reference, then dive into evaluating and improving designs. Attendees will work in groups to examine parts to identify where non-conformities will occur and methods to improve those risks.

Course Highlights:

• Part design – Wall Thickness, Flow Length, Features, Radius, Draft, Gloss
• Material – Thermoplastics or Thermosets, Melt Flow Index (MFI), Shrink Rate
• Tooling – Steel, Line of Draw, Actions, Melt Delivery, Ejection, Surface Finish
• Machine – Clamp Tonnage, Injection Volume, Injection Flow Rate, Injection Plastic Pressure
• Processing – Melt Temperature, Flow Rate, Pressure Gradient, Cooling Rate & Time
• Non-Conformities, Warp, Short Shots, Sinks, Voids, Bubbles, Jetting, Blush, Gloss, Knit Lines
• Tolerance – First Article Inspection, Critical, In-Process
• Design for manufacturability (DFM) – Part Design Checklist, FMEA

Pricing (includes books, tests, and lunch each day):
Jabil employee: $2,860

Non-Jabil employee: $2,860 (this includes customers and key partners, but not competitors).