Technical document

How to Effectively Reduce Production Costs of Precision Injection Molding

2025-07-02 14:54:35 Precision Injection Molding
In the fiercely competitive manufacturing environment, cost control is crucial for precision injection molding enterprises to achieve profit growth. Here are key strategies combining new-era technologies and management ideas:
1. Raw Material Cost Optimization
  1. 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.

  1. 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.

  1. Secure favorable procurement terms: Sign long-term agreements with suppliers for tiered pricing (3%-5% discount for annual purchases over 500 tons).

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2. Mold Lifecycle Cost Management
  1. 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.

  1. 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).

  1. Implement regular maintenance: Conduct full inspections (polishing, lubrication) every 5,000 cycles via maintenance records, slashing unexpected repair costs by 30%.

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3. Production Efficiency Improvement
  1. 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%).

  1. Introduce automation: Deploy six-axis robots for picking, inspection, and stacking to reduce 2 operators/equipment; raise yield from 95% to 99%.

  1. Use real-time monitoring: Apply MES systems to alarm for ±2℃+ injection molding machine temperature fluctuations, lowering defect rates from equipment issues.

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4. Equipment & Manpower Collaboration
  1. 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.

  1. Conduct preventive maintenance: Change hydraulic oil and check screws every 2,000 hours to reduce unplanned downtime by 50%.

  1. 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.

  1. Adopt digital scheduling: Adjust shifts dynamically based on orders to avoid labor idleness.

In conclusion, precision injection molding cost control requires synergy across materials, molds, production, equipment, and manpower. Integrating intelligent technologies and refined management ensures cost reduction while maintaining precision, enhancing competitiveness.

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