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SIPOC templates

SIPOC — Injection Moulding Cell

Fixes the boundary of a seven-step moulding cell from resin release to finished-goods booking, checking both scope ends against the process and scoring three tiles — 3.2% scrap against a 1.5% target, 47 s cycle against 42 s, 34-minute changeover against 20.

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Injection moulding cell — housing part 4471Scope · Resin released to cell → Pallet booked into finished goodsProcess ownerCell leader, Moulding 2Scrap rate3.2%target 1.5% · +1.7%Cycle time47target 42 · +5 sMould changeover34target 20 · +14 minSSuppliers4IInputs5PProcess7OOutputs4CCustomers3Resin supplierMasterbatch supplierTool roomProduction planningVirgin PP resinCTQMoisture below 0.02% after3 hours drying at 80 CColour masterbatchMould tool 4471-BReleased by the tool roomwith cavity count andlast-service dateMachine setup sheetApproved first-off sampleCTQSigned by quality beforethe automatic cycle startsMoulded housingsCTQNo short shots, flash under0.1 mm, weight 84.5 g ± 0.8 gRegrind for reuseFirst-off inspectionrecordScrap ticketsReason coded against theeight standard defect classesAssembly line 3Quality engineeringWarehouse1Release resinto cell2Set tool andpurge3Run first-offapproval4Mould inautomaticcycle5Degate andinspect6Pack andlabel7Book intofinishedgoods4 suppliers · 5 inputs · 7 process steps · 4 outputs · 3 customers2 of 5 inputs have no stated requirement: “Colour masterbatch”, “Machine setup sheet”.2 of 4 outputs have no stated requirement: “Regrind for reuse”, “First-off inspection record”.Scope starts at “Resin released to cell”, matching step 1 “Release resin to cell”.Scope ends at “Pallet booked into finished goods”, matching the last step “Book into finished goods”.Metric “Scrap rate” misses target: 3.2% against 1.5%, a gap of 1.7 %.Metric “Cycle time” misses target: 47 against 42, a gap of 5 s.Metric “Mould changeover” misses target: 34 against 20, a gap of 14 min.

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title "Injection moulding cell — housing part 4471"
scope "Resin released to cell" -> "Pallet booked into finished goods"
owner "Cell leader, Moulding 2"
metric "Scrap rate" target: 1.5% actual: 3.2%
metric "Cycle time" target: 42 actual: 47 unit: s
metric "Mould changeover" target: 20 actual: 34 unit: min

sources: Resin supplier, Masterbatch supplier, Tool room, Production planning
inputs: Virgin PP resin, Colour masterbatch, Mould tool 4471-B, Machine setup sheet, Approved first-off sample
steps: Release resin to cell | Set tool and purge | Run first-off approval | Mould in automatic cycle | Degate and inspect | Pack and label | Book into finished goods
outputs: Moulded housings, Regrind for reuse, First-off inspection record, Scrap tickets
clients: Assembly line 3, Quality engineering, Warehouse

requirement input "Virgin PP resin": "Moisture below 0.02% after 3 hours drying at 80 C" (CTQ)
requirement input "Mould tool 4471-B": "Released by the tool room with cavity count and last-service date"
requirement input "Approved first-off sample": "Signed by quality before the automatic cycle starts" (CTQ)
requirement output "Moulded housings": "No short shots, flash under 0.1 mm, weight 84.5 g ± 0.8 g" (CTQ)
requirement output "Scrap tickets": "Reason coded against the eight standard defect classes"