This Standard Operating Procedure (SOP) covers the complete injection molding process for manufacturing Heavy Duty Brackets (Part P-7890-X). The procedure includes machine setup, operation, quality control, and shutdown protocols.
Injection molding equipment operates at high temperatures (up to 400°F) and pressures (up to 20,000 PSI). Failure to follow safety procedures may result in serious injury or death.
Always verify that all safety guards are in place and functioning before operating the machine. Never bypass safety interlocks.
Complete the Pre-Operation Checklist (Form QC-101) and obtain supervisor approval before proceeding.
Apply a thin, even coat of mold release agent before the first cycle to prevent sticking and ensure part quality.
Verify the following machine parameters match job specifications:
| Parameter | Target Value | Tolerance |
|---|---|---|
| Barrel Temperature Zone 1 | 380°F | ±5°F |
| Barrel Temperature Zone 2 | 390°F | ±5°F |
| Barrel Temperature Zone 3 | 395°F | ±5°F |
| Nozzle Temperature | 400°F | ±5°F |
| Mold Temperature | 85°F | ±5°F |
| Injection Pressure | 15,000 PSI | ±500 PSI |
| Cycle Time | 45 seconds | ±2 seconds |
Never attempt to purge or inject material until all temperature zones have reached setpoint and stabilized. Premature operation can damage the screw and barrel.
Save first purged material for color comparison. This helps identify any contamination issues during production.
Inspect the first good part and obtain Quality Control approval before proceeding with production run.
During production, continuously monitor the following:
Set up sample parts display showing acceptable and defective examples. This helps maintain consistent quality standards throughout the shift.
If minor adjustments are needed:
Perform visual inspection on sample parts every 10 units. Reject parts with:
Perform dimensional inspection every hour using calibrated instruments:
| Dimension | Nominal | Tolerance | Inspection Method |
|---|---|---|---|
| Overall Length | 150.0 mm | ±0.5 mm | Digital Caliper |
| Overall Width | 75.0 mm | ±0.3 mm | Digital Caliper |
| Wall Thickness | 4.0 mm | ±0.2 mm | Ultrasonic Gauge |
| Mounting Hole Diameter | 12.0 mm | ±0.1 mm | Pin Gauge |
| Part Weight | 125 g | ±5 g | Digital Scale |
Record all measurements on Form QC-205. If any measurement falls outside tolerance, notify supervisor immediately and halt production.
For each defective part:
Complete comprehensive First Article Inspection (FAI) for:
Possible Causes:
Corrective Actions:
Possible Causes:
Corrective Actions:
Possible Causes:
Corrective Actions:
Possible Causes:
Corrective Actions:
If issues persist after following troubleshooting steps, stop production and contact your supervisor or maintenance technician. Do not continue producing defective parts.
Contact maintenance immediately if you observe:
Purge with purging compound or next scheduled material to prevent material degradation during downtime.
Ensure all production documentation is complete and accurate before leaving the workstation. Incomplete records may delay shipment.
Emergency: 911
Plant Security: Ext. 5000
Maintenance Emergency: Ext. 5100
Safety Supervisor: Ext. 5200
Your safety and the safety of your coworkers is the top priority. When in doubt, stop the machine and ask for help. Never compromise safety for production.
All incidents must be reported immediately, including:
Complete Form SAFE-001 and submit to safety supervisor within 24 hours.
Document Control: SOP-IM-001 Rev. 2.3 | Effective Date: November 2025
Next Review: May 2026 | Document Owner: Manufacturing Engineering
This document is controlled. Unauthorized copies are not valid. Always use the latest revision from the document management system.
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