Plastics EngineeringCUTTING-EDGE CONTINUING EDUCATION - FALL 2010

SCE-PLASTICS.UWM.EDU

OptimizePerformance.InspireInnovation.Plastics Engineering is more complex than ever. To answer increaseddemands, you must be at the forefront of innovation and efficiency.

Thankfully, you’ve found cutting-edge continuing education. Frombasic parts to advanced mold design, our comprehensive coursesmaximize your knowledge, productivity and marketable skills.

Each course is led by practitioner instructors who have the real-worldexperience to ensure your real-life success. They are teachers,innovators and most importantly they are engineers who understandthe field.

For more details and to learn how we can bring courses to you,contact me at 414-227-3121 or mvedula@uwm.edu.

Sincerely,

Murali VedulaEngineering Program DirectorUWM School of Continuing Educationsce-eng.uwm.edu

MURALIVEDULAProgram Directormvedula@uwm.edu 414-227-3121

Dr. Murali Vedula worked in engineering atDow Chemical Company and StructuralComposites Industries for several years beforejoining UWM in 1997.

For the past 13 years, Dr. Vedula has used hisengineering knowledge and contacts toidentify professional development needs,including elastomer and plastics technology,electrical engineering, innovation, mechanicaland industrial engineering, and Six Sigma.In response to changing demographics, hehas restructured Six Sigma certificateprograms to meet the needs of the serviceindustry. In add ition, he recently began offeringan Office Lean certificate program and hasbeen involved with internal Lean training. Hislatest emphasis is on innovation. He currentlyserves on the Board of the Society of PlasticsEngineers Milwaukee Chapter.

DEBRAO’NEILProgram Associate oneil@uwm.edu414-227-3180

Debra O’Neil has been with the School ofContinuing Education for over15 years, nineof which she was a program associate supporting public and corporate Engineeringprograms. She assists with the coordinationof course scheduling, materials assembly,program content, marketing, inquiries andbilling. She is customer service oriented andenjoys working with program participants.

TABLE OF CONTENTSPlastics Technology

Plastic Injection Mold Design Basics ............................................4

Plastic Injection Mold Design Advanced ......................................5

Innovative Solutions for Plastic Part Production ..........................6

Designing Plastic Parts for the Injection Molding Process ............7

Innovation

Accelerated Product Development - Using Product Realization............................................................8

Quality/BPI

Six Sigma Black Belt ....................................................................9

Instructors ....................................................................................10General Information ..................................................................11Onsite Training ............................................................................Back Cover

HIGHLY RECOMMEND TO SUPERVISORS AND ENGINEERS

DESIGNING PLASTIC PARTS."

- Sunil Dasara, Terumo Heart Inc.

"VERY INFORMATIVE,A LOT OF INFORMATIONWAS COVERED IN A

VERY SHORT AMOUNT OF TIME."

- Anthony Makusi, Tech Molded Plastics, L.P.

Learn howto earn a

Plastics TechnologyCertificate 414-227-3121

or visit

sce-plastics.uwm.edu

4 sce-plastics.uwm.edu 414-227-3121

PLASTIC INJECTION MOLD DESIGN BASICSGain a thorough understanding of injection mold design fundamentals. This practicalcourse gives those involved with injection molds a comprehensive look at injection molddesign and demonstrates how to contribute to the success of projects. It offers a uniqueblend of very detailed mold design concepts set forth in the context of the design processas a whole. On the final day students participate in the mold design process.

Who should attendAnyone responsible for procuring, evaluating, building or designing injection mold tools,including tooling engineers, buyers, toolmakers, mold designers, product designers,managers and molders.

COURSE OUTLINE

Plastics.

Mon.-Wed., Aug. 23-25, 20108am-4:30pmInstructor: Jim WalshFee: $990CEUs: 2.0Program No. 4830-8313

Mon.-Wed., Apr. 25-27, 20118am-4:30pmProgram No. 4830-8305

Introduction and OverviewThe Anatomy of a Mold

- Mold Types • Stripper plate molds • Unscrewing molds • Quick change molds • Hot runner molds • Shuttle molds- Basic Mold Construction • Use and placement of bolts

and dowels • Major suppliers and differences

between them • How to specify and order

mold bases and components- Common Components

and Their Function • Leader pins, return pins, support

pillars, rest buttons etc.

The Molding Press- How the mold interfaces with

the press- Horizontal and vertical clamp- Shuttle and rotary presses

Plastic Resin Fundamentals- Amorphous and semi-crystalline

- Basic properties and how they affect the mold design

Shrink- How to use shrink to your advantage- Factors that affect shrink and warp

Plastic Product Design Fundamentals- Common errors- What the mold designer needs to look

for in a product design

Sprue, Runner and Gate- Common gate design errors- Runner sizing guidelines- Runner pullers

Ejection- Determining ejector place- Pin orientation methods- Knock-out patterns- Return pins and springs

Basic Mold Inserting- Solid vs. split construction- Criteria for inserting

Slides and Lifters- A thorough look at how

to mold undercuts- Typical slide and lifter construction- Mechanical vs. hydraulic

Cavity Layout- How to efficiently “place“ the cavities in

the mold and choose the best parting line- How it affects runners, ejection

and gates

Cooling- The economic effect of cooling design- General rules for waterline placement- Thermal conductivity of various

tool steels

Venting- Venting of runners- How venting affects the molded part- Why this should NOT be overlooked

Mold Steel - What to look for in a mold steel- A discussion of steel hardness- Alternate materials used in molds

Plating and Polishing- A selection chart for mold coatings- When and why to use plating

Mold Design from a Project PerspectiveStudent Design Projects

- Students will be split into groups to work on actual design projects

sce-plastics.uwm.edu 414-227-3121 5

PLASTIC INJECTION MOLD DESIGN ADVANCEDYou’ve got the basics, now it’s time to move to the next level. Examine the inner workingsof injection molds, including cost saving techniques. Participants are encouraged to bringcurrent problems to be addressed.

Who should attendMold designers, tooling engineers and toolmakers, product designers, buyers, molders,and managers.

Requirements: Completion of Plastic Injection Mold Design Basics or a solidknowledge of the subject matter.

COURSE OUTLINE

Introduction and Overview- Course objectives

Molding Surface Tolerances- The various fits in a typical mold- The tolerances that should be maintained- How the product tolerances affect tool tolerances- How it affects mold cost

Mold Strength and Preformance- Understanding the forces acting against a mold- Various calculations- Designing for strength and longevity

Mold Alignment and Interlocking- Various methods of insuring mold alignment- Balancing of forces in a mold- Core shift causes and fixes- How it affects mold longevity

Advanced Parting Line and Shut-off Development- A detailed look at shut-off designs- Contoured and stepped parting lines- Common product design errors that complicate parting lines- Examples of complex parting lines

Advanced Slide and Lifter Design- When to use a lifter instead of a slide- Methods of slide actuation- A look at the forces involved- Proper heel block and gib design- The use of springs with slides- How and when to delay slides- Dual action slides- Slides in the stationary half

- Slide alignment- Designing slides for low maintenance- Determining slide travel- Alternate methods of molding undercuts- Stripping of undercuts- Floating inserts to release undercuts- Collapsible and expandable cores- Slide retention methods

Advanced Cavity and Core Inserting- A thorough look at every aspect of inserting- Criteria for deciding whether or not to insert- Pins and other round inserts- Inserting slides and lifters- Laminated inserts- Gate inserts- How inserting affects manufacturing- The economics of inserting- Assembling of inserts- Sub assembly design concept- Quick change inserts

3D Modeling and Mold Design- Improving translation between CAD systems- General problems with CAD exchange- Tips and tricks- Translation options

Mold Monitoring- Pressure transducers- Thermocouples- Proximity and limit switches- Vision systems

Thu.-Fri., Aug. 26-27, 20108am-4:30pmInstructor: John VosmeierFee: $790CEUs: 1.4Program No. 4830-8306

Thu.-Fri.,Apr. 28-29, 20118am-4:30pmProgram No. 4830-8307

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INNOVATIVE SOLUTIONS FOR PLASTICPART PRODUCTIONLearn to overcome challenges facing the injection molding industry with practicalsolutions. Explore ways to ensure your needs align with equipment. Identify day-to-dayissues that arise surrounding injection molded part quality. Explore solutions and learninnovative ideas to produce high quality, efficient and economical parts for injectionmolding.

Who Should AttendManufacturing and molding engineers involved with injection molded plastic parts. Also,technical professionals involved with manufacturing injection molded plastic parts, toolingengineers, mold designers, product designers, project engineers and quality control personnel.

Thu.-Fri., Oct. 21-22, 20108am-4:30pmInstructors: John Vosmeier, Nick BrownFee: $790CEUs: 1.4Program No. 4830-8310

Thu.-Fri., May 19-20, 20118am-4:30pmProgram No. 4830-8311

The EquipmentIntroduction & Course Outline ReviewMolding process particulars…Good molding practices

- Selecting an injection machine to meet or exceed your needs.

- Sizing the equipment list to the operation- Auxiliary equipment needed- Cooling systems

Review Scientific Injection Molding PrincipalsMold construction review (various types)

- Review injection mold types.- What to expect from each mold type- Limitations of each mold type- Selecting the correct design (guidelines)- Maintaining your injection molds

Product design issues- Design issues- Designing to fit the need- Designing pitfalls

Class Project Assigned (Individuals)Problems & SolutionsReview Class ProjectMachine problems

- What kind of issues can be machine related?

- Injection machine limitations- What are common machine failures and how

to prevent them- Maintaining your injection machine

Processing / Plastic part problems- Gate Blush- Flow lines / Streaks- Hard to fill parts- Delaminations, Over packing, Excessive Shrinkage, Short

Shots,- Splay / Silver Streaks, Surface Blemishes, Flash, Warpage,- Weak Weld Lines, Bubbles vs. Voids, Black Specks.

Determining root cause & solutions of each defectResin problems

- Correct selections vs. incorrect selections- Fillers and additives- Shrinkages- Mechanical properties

Mold problems- Common issues- Preventing those issues in design- Correcting them once they occur- Don’t make matters worse by poor decisions

Final Class Project….Groups

COURSE OUTLINE

sce-plastics.uwm.edu 414-227-3121 7

DESIGNING PLASTIC PARTS FOR THE INJECTION MOLDING PROCESSTo design a high quality injection molded part, the designer must select an appropriateplastic material formulation, develop a functional design and work within themanufacturing limitations associated with the injection molding process. Get acomprehensive overview of plastic part design for the injection molding process. Thiscourse covers the fundamentals of plastic materials, behavior and selection, engineeringdesign, manufacturing considerations and assembly methods.

Who should attendEngineers and designers who are accustomed to working with metals and are faced withmetal to plastic concerns.

Requirements: You should have some knowledge of plastic materials, injection molding and engineering principles, although the basics are introduced.

Mon.-Wed., Nov. 8-9, 20108am-4:30pmInstructor: Nick SchottFee: $790CEUs: 1.4 Program No. 4830-8308

An Introduction to Plastic Materials- Historical Development- Fundamental Concepts- Molecular Weight- Repeat Unit Structure- Morphology- Effect of Additives- Mechanical Property Overview- Flow Property Overview- Advantages of Plastic Materials- Limitations of Plastic Materials

Review of Injection Molding EquipmentReview of the Injection Molding ProcessReview of Injection MoldsDesign Considerations for Injection Molded Parts

- Mold Filling Considerations- Effect of Gate Location and Type- Molecular and Fiber Orientation- Mold Filling Pressure Drop

- Flow Leaders and Flow Hesitation- Mold Filling Simulations- Runner Balancing and Family Molds- Weld or Knit Lines- Shrinkage and Warpage Considerations- Part Ejection Considerations

Mechanical Behavior of Plastic MaterialsApproaching Plastic Product Development

- Establishing End Use Requirements- Conceptual Design- Initial Candidate Material Selection Procedures- Design Based Upon the Materials Selected- Final Materials Selection- Manufacturing Related Design Modifications- Prototyping and Testing- Production Tooling and Manufacturing- Plastic Part Prototyping Techniques- Assembly Techniques for Injection Molded Parts

COURSE OUTLINE

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ACCELERATED PRODUCT DEVELOPMENT - USING PRODUCT REALIZATIONLearn innovative approaches and design processes for developing new products with multi-disciplinary teams often located worldwide. Study strategies for optimizing multiple phasesof the product realization process including: requirements definition, concept generation,concept selection, prototype generation, design for manufacturing, testing and marketpenetration. Work on actual new product concepts and discover each phase of thenonlinear process to produce a working prototype.

Who should attendEngineers, researchers, scientists, managers and technical leaders of new product development,research and development, manufacturing, marketing and supplier management.

Mon.-Tue., Aug. 19-20, 20108am-4:30pmInstructor: Michael R. LovellFee: $790CEUs: 1.4Program No. 4830-8501

Introduction and OverviewCourse Objectives

- Global Landscape of Technology and Innovation- Overview of Product Realization Process- How new techniques were developed- Product Development Exercise

Creating Successful Teams- Team Building Exercise- Understanding teams- Roles of team members- Best Practices and Lessons Learned

Project Planning- Role and Rules for project planning- Project planning tools- Project Planning Exercise

Developing Project Requirements- Understanding internal requirements- Unique product orientations- Customer needs analysis

Concept Generation- What is a design concept?- Potential Failures

- Five Step Approach to generating innovative concepts- Concept generation exercise- Concept Selection- Potential Failures- Concept Screening- Concept Scoring- Concept Selection exercise

Design for Manufacturing- Understanding product realization from business perspective- Minimize costs while maximizing performance

Prototyping- Role of prototyping in design innovation- Prototyping processes- When to generate prototypes

Testing- Developing robust test plans- Role of failure in innovative design

Penetrating the Market- Making products to gain market niche- Ensuring product safety and reliability

Innovation.COURSE OUTLINE

COURSE OUTLINE

sce-plastics.uwm.edu 414-227-3121 9

SIX SIGMA BLACK BELTSix Sigma is a highly disciplined improvement methodology that helps organizationsachieve optimal performance in all operations. Learn methods to identify how many“defects” you have in a process and systematically determine how to reduce them to get asclose to zero defect as possible.

Who should attendAnyone wanting to improve quality, identify and reduce sources of variation and reducethe rate of non-conformance in products or services.

Module I Tue.-Thu., Sept. 14-16, 2010Fee: $1295CEUs: 2.0Program No. 4830-8101

Module II Tue.-Wed., Oct. 5-6, 2010Fee: $1195CEUs: 1.4Program No. 4830-8102

Module III Tue.-Wed., Oct. 26-27, 2010Fee: $1195CEUs: 1.4Program No. 4830-8103

Module IV Tue.-Thu., Nov. 16-18, 2010Fee: $1295CEUs: 2.0Program No. 4830-8104

8am-4:30pmInstructor: Davis R. Bothe

Quality.

MODULE IDefine & Measure

- Overview of Process ImprovementStrategies

- Why Six Sigma? The DMAIC (Define, Measure, Analyze, Improve,Control) Roadmap

- Roles of Champions, Master BlackBelts, and Blak Belts

- Process mapping – flowcharts- Data collection and sampling

techniques- Basic statistics –

location versus variation- Control charges –

variable and attribute- Control charts for short

production runs- Subgroup statistics versus

process parameters- Rationale for the 1.5σ symbol

MODULE IIMeasure & Analyze

- Gage capability studies- Estimating process parameters- Short- versus long-term variation- Process and machine capability studies- Converting process performance

to a σ level- Effect of the 1.5σ shift on capability- Dealing with non-normal

distribution- Rolled throughput yield

MODULE IIIAnalyze & Improve

- Check sheets and matrix diagrams- Multi-vari analysis for families

of variation- Component swapping for large

assemblies- Brainstorming and cause-and-effect

diagrams- Multi-voting and decision-making

by consensus- Regression analysis and scatter

diagrams- Comparison testing between

“good” and “bad” parts- Analysis of means (ANOM)

MODULE IVImprove & Control

- Hypothesis testing and confidence intervals

- Analysis of variance (ANOVA)- Developing feasible solutions- Solution FMEAs and pilot studies- Mistake proofing – poka-yoke- Advanced control charting concepts- Corrective action plans –

work instruction- Preserving the process

knowledge gained- Kaizen for continuous improvement

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Instructors.

Plastics.Nicholas W. Brown has worked in the injection molding industryfor over 20 years. He attributes his unique perspective on moldingto the fact that he started his career as a molding technician and hasheld such positions as process engineer, manufacturing engineer,plant superintendent and plant engineer. For the past 12 years hehas been the molding manager for a world-wide consumer productscompany in the department he founded. The company runs a 24/7operation, which has averaged 358 days of production per year. Anavid student, Mr. Brown earned a Bachelor’s degree in Business in2000 and recently received his MBA. He received the Master Molder1 and Master Molder 2 certifications from RJG in 2000.

Nick R. Schott completed his B.S. in chemical engineering at UCBerkeley and then went on for an M.S. and Ph.D. in chemicalengineering at the University of Arizona. Professor Schott has beenat the University of Massachusetts Lowell for the past 32 years. Hehas taught courses in plastics product design, plastics injection molddesign, processing and process control. He is an active researcherand a worldwide lecturer on these subjects. Professor Schott wasnamed a fellow of the SPE in 1986 and is a founding member of theSPE Product Design and Development Division. He is an editor ofvarious books and has authored or co-authored numerous papersin the field of plastics engineering.

John Vosmeier has worked as a design manager, senior toolingengineer, senior mold designer and is currently the tooling managerfor a consumer products company purchasing molds in the U.S. andworldwide. He has worked with custom and proprietary moldersover the years as well as owning DeJohn Innovative Plastics, a designand consulting firm since 1987. The business specializes in programdevelopment of injection molds and plastic products. Mr. Vosmeierhas worked in the U.S. as well as Canada, Portugal, Mexico, Taiwan,Hong Kong and China. His extensive travels over the years havegiven him the vehicle needed to accumulate a vast amount ofknowledge and information which he uses to construct curriculum.He holds a degree in tool engineering technology, is a seniormember of SPE and since 1995, he has been very active indeveloping new educational curriculum for the plastics industry.

Jim Walsh has been involved with injection mold engineering for30 years and has extensive hands on experience in all aspects of themold design and development process. Having worked for manyyears as a mold designer, he has hundreds of successful mold designprojects to his credit. His background ranges from small, veryintricate molds for the automotive and electronic connectorindustries to larger molds for consumer products. During his career,Mr. Walsh has held positions of senior mold designer, engineeringmanager, and is currently a senior plastics/ tooling engineer in theautomotive industry and an independent consultant.

Innovation.Michael R. Lovell was hired as Dean of Engineering at theUniversity of Wisconsin-Milwaukee in August of 2008. Hepreviously served as the Associate Dean for Research in the Schoolof Engineering at the University of Pittsburgh where he heldappointments in the industrial, mechanical and bioengineeringdepartments. During his tenure in Pittsburgh, Dean Lovell servedas the Executive Director of the Swanson Center for ProductInnovation where he spent eight years mentoring more than 200project teams through the product realization process. Afterreceiving several grants from the National Science Foundation, hewas able to perform in-depth research on the product developmentteams he mentored. Based on this research, Dean Lovell developedunique methodologies that increased the likelihood of a teamcreating an innovative product from 50-80 percent. Utilizing hismethodology, he mentored student teams that developed 224 newproducts and formed eight companies over a four-year period. Hehas launched an Institute for Industrial Innovation at UWM.

Quality.Davis R. Bothe has over 27 years of experience working, teachingand consulting in the field of process improvement. His credentialsinclude: ASQ Fellow, IQI certified Master Black Belt, ASQ certifiedQuality Engineer, ASQ certified Reliability Engineer, member ofthe US Technical Advisory Group to the ISO Technical Committee69 on Applications of Statistical Methods, B. S. in appliedmathematics and physics, and a Master’s degree in businessadministration. He is author of the quality improvement books"Industrial Problem Solving," "Measuring Process Capability," and"Reducing Process Variation." He is listed in the first edition of "TheInternational Who's Who in Quality." Mr. Bothe has worked atNASA, General Motors, Eastern Michigan University and currentlyserves as the director of Quality Improvement for the InternationalQuality Institute.

sce-plastics.uwm.edu 414-227-3121 11

General Information.REGISTRATIONPhoneMon.-Fri., 8am-5pm Central800-222-3623 (toll free)414-227-3200 (local)

Onlinesce-registration.uwm.edu

FeeThe fee includes program materials, continental breakfast, lunchand breaks. Lodging and other meals are not included.

LodgingYou may make your own lodging arrangement at the facility ofyour choice. Hotel information will be mailed with yourenrollment confirmation. When contacting the hotel, mentionthat you will be attending a University of Wisconsin–Milwaukeeseminar to receive a discounted rate.

CancellationsPlease call 414-227-4100 at least seven days before the coursestarts for a refund. Cancellations received less than seven daysbefore the start of the course will be subject to a late cancellationfee. You may enroll a substitute at any time before the coursestarts, or you may apply the enrollment fee to a future course.

In the event the School cancels a class, the University ofWisconsin–Milwaukee will reschedule, refund fees or apply thefee payment to any other School of Continuing Educationengineering program offered in the next 12 months. Liability ofcancellation is specifically limited to the amount of the pre-paidclass fee and excludes any incidental or consequential damages.

Continuing Education Units (CEUs)All programs in this catalog carry Continuing Education Units(CEUs). CEUs are a means of recognizing and recordingsatisfactory participation in nondegree programs. One CEU isawarded for each 10 contact hours (or equivalent) in anorganized continuing education experience. All CEUs earnedthrough the University of Wisconsin–Milwaukee School ofContinuing Education noncredit programs become a part ofyour permanent record.

ParkingParking is available in the Shops of Grand Avenue parkingstructure and other adjacent lots. The School of ContinuingEducation provides a parking discount for program participants.Inquire for details.

DirectionsFor the latest information on getting to and from the School ofContinuing Education, visit sce-directions.uwm.edu. Thewebpage includes access to printable color PDFs of currentmaps, information about parking and public transportation, andother details relevant to our location.

For Further InformationContact Murali Vedula at 414-227-3121 or mvedula@uwm.edu.

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ONSITE TRAINING Capitalize on our CapabilitiesAny program can be designed to meet your organization's unique and specificemployee development needs. Consider the advantages to partnering with UWM SCE.

Contain Costs by eliminating or reducing travel, food and lodging expenses.

Maximize Convenience by choosing your optimal dates, times and location.

Save Time with staff spending fewer hours away from work.

Build Teamwork through group brainstorming and shared learning experiences.

Custom Tailor Content to your needs to accomplish specific organizationalobjectives. Or, use the curriculum as-is.

For more information, contact Murali Vedula at 414-227-3121 or mvedula@uwm.edu.

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