RJG Blog // DECOUPLED MOLDING® III: Paving the Way for Quality Moulding with Less Staffing

In the modern manufacturing market, companies are tasked with maintaining high-quality output while managing lean operations, often with fewer available workers. For injection moulders, finding ways to uphold these standards with limited staff is more crucial than ever. DECOUPLED MOLDING III (DIII) offers a solution by facilitating more streamlined, automated processes that bring us closer to autonomous moulding. This advanced methodology not only ensures the quality and consistency of moulded parts but also empowers companies to leverage automation to reduce dependence on manual labour. In this blog, RJG will delve deeper into the principles of DECOUPLED MOLDING III, explore its benefits for lean manufacturing, and discuss how it supports the shift towards autonomous moulding.

What Is DECOUPLED MOLDING III?

At its core, DECOUPLED MOLDING III is a scientific moulding approach that separates each stage of the moulding process to improve repeatability and quality. It goes beyond traditional moulding techniques by isolating key phases like filling, packing, and holding, ensuring precise control at each step. This method reduces variation and increases part quality, even in high-demand environments where consistent results are critical.

Where traditional moulding requires continuous operator oversight to adjust for inconsistencies, DIII empowers moulders to set up robust, self-regulating systems. This translates to a smoother, more controlled process that can detect and adjust to minor fluctuations without manual intervention. With DIII, injection moulders can reduce labour costs, as they no longer need to rely heavily on operators to make in-process adjustments.

The Shift Toward Autonomous Moulding

DECOUPLED MOLDING III brings moulders a step closer to true autonomous moulding, where machines operate independently with minimal human intervention. By automating the adjustment processes, DIII reduces the need for skilled operators to manage each cycle. Ever-evolving technologies like RJG’s CoPilot, use real-time data to monitor and adjust the moulding process, allowing automated adjustments without human input.

How DIII Supports Lean Manufacturing

For manufacturers aiming to optimise production with lean staffing, DECOUPLED MOLDING III is an invaluable asset. DIII allows fewer staff members to manage more machines, as it minimises the need for constant supervision and hands-on adjustments. With tools like RJG’s training and technology solutions, operators and technicians can be effectively upskilled, enabling them to oversee a larger scope of responsibilities with confidence.

Upfront Investment Yields Long-Term Savings and Efficiency

While investing in the technology required for DECOUPLED MOLDING III and automation may come with significant upfront costs, the return on investment (ROI) can be substantial. By making better parts faster and with greater precision, manufacturers can reduce scrap rates and improve overall efficiency. Additionally, automated systems help minimise downtime, as machines can self-adjust and detect issues before they become major problems. This efficiency leads to higher output and fewer interruptions. Moreover, the reduction in labour requirements translates to cost savings on salaries and benefits, making the initial investment worthwhile over time.

By embracing DECOUPLED MOLDING III and automation technologies, companies can achieve high-quality moulding processes with fewer hands on deck, leading to cost savings and production efficiency all while improving part quality. This combination is paving the way for the future of autonomous moulding and enabling a more resilient, adaptable manufacturing environment.

Read more from RJG here.

RJG
+44 (0)1733 232211
Website
Email