Methodology to reduce nonconformities in an injection process: an empirical study

This study aimed to create a control methodology to avoid problems of nonconformities in an industry that is in the process of installation in the industrial hub of Manaus, in the Brazilian Amazon. These nonconformities appear as injection failures, injection burrs, lack of impact resistance, and lack of weight control of each injected pot. Reducing these nonconformities will allow the company to have quality products in the pots and lid injection process. The intention is that the control is based on tools from the RAMI 4.0 architecture so that you can parameterize and control all stages of the production process. The scientific-technological method was used in its second part, which aims to generate a technological product. The simulated results showed almost complete elimination of warping (991 to 7), injection failures (794 to 14), and injection burr (1,377 to 12) daily. The total number of failures dropped from 3,162 to just 33. The simulated results allowed the elaboration of a solution based on 1) the integration of the corporate control system, 2) the application of digital twin technology, and 3) the use of IoT for data collection, transmission, and analysis. The conclusion shows that the Rami 4.0 architecture is efficient and effective in dealing with these adversities in production processes.