Why a non-standardized process cannot lead to optimization

Context

Production by injection molding without formal technological standardization. Parameters are kept on the machine but were not systemically controlled.

Initial Condition

Frequent parameter adjustments, uneven cycle time, and deviations in mass and dimensions between shifts.

Key Technological Problem

Lack of technological cards, absence of protocols for approving the first piece, and undefined parameter ranges.

Technical Consequence

Without a defined starting point, the process varies. Variation prevents optimization as stability must precede efficiency.

Implemented Measures

Technological cards have been introduced for each tool-machine-material combination, parameter ranges defined, and records maintained by shifts.

Effect

Reduced variability of parameters, stabilized cycle time, and enabled further optimization.

Engineering Conclusion

Optimization is not possible without standardization. An unstable process cannot be optimized – it is constantly corrected.

If your production depends on individuals instead of systems – let’s analyze it.