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Welcome
1 Proprietary & Confidential | marnus.dutoit@thermofisher.com | 28-October-2021
A Day in the life of a Manufacturing Engineer at Thermo Fisher
Introducing
2 Proprietary & Confidential | marnus.dutoit@thermofisher.com | 28-October-2021
Marnus du Toit
Manufacturing Engineer, Laboratory Plastics Division
• ND.: Plastics Technology, Cape Peninsula University of Technology, 2001
• B.Eng.: Global Management and Manufacturing (GMM), Aarhus University, 2014
• M.Sc.: Operations and Management Engineer (OME), Aalborg University ,2018
3 Proprietary & Confidential | marnus.dutoit@thermofisher.com | 28-October-2021
4 Proprietary & Confidential | marnus.dutoit@thermofisher.com | 28-October-2021
5 Proprietary & Confidential | marnus.dutoit@thermofisher.com | 28-October-2021
INJECTION MOULDING MACHINES and AUTOMATED
PRODUCTION LINES with
3000TONES OF POLYMER USAGE PER YEAR
R&D – QA – QC – SUPPLY CHAIN – PRODUCTION PLANNING AND CONTROL –
LEAN AND BUSINESS OPTIMIZATION – FINANCE – VALUE STREAM MANAGEMENT –
WAREHOUSE AND LOGISTICS – MAINTENANCE – FACILITY MANAGEMENT – GLOBAL
SUPPLY – ACCOUNDTING – ENGINEERING -HEALTH AND SAFETY – BUSINESS
INTELLEGENCE – METROLOGY – TECHNICAL DOCUMENTATION – NUNC ATOM
500 EMPOYEES – 3 SHIFTS 24/7 PRODUCTION
6 Proprietary & Confidential | marnus.dutoit@thermofisher.com | 28-October-2021
7 Proprietary & Confidential | marnus.dutoit@thermofisher.com | 28-October-2021
8 Proprietary & Confidential | marnus.dutoit@thermofisher.com | 28-October-2021
9 Proprietary & Confidential | marnus.dutoit@thermofisher.com | 28-October-2021
10 Proprietary & Confidential | marnus.dutoit@thermofisher.com | 28-October-2021
On a STRATIC LEVEL I manage highly skilled, cross
functional, internal and external EXPERTS to deliver
RESULTS within the TIME available
On a TACTICAL LEVEL I run COMPLEX analysis to
generate understanding and KNOWLEDGE though a
systematic approach
On a OPERATIONAL LEVEL I support CRITICAL functions
to meet customer EXPECTATIONS
11 Proprietary & Confidential | marnus.dutoit@thermofisher.com | 28-October-2021
Business case formulation – Project Budget Estimation -
Payback calculation – Acquisition Request – Purchase Order –
Supplier Relationship Management – Economics – Negotiation
Project Design Charter and Scope – Timeline – Project Risk Analysis
& What If’s – Steering Committee Reports – Resource Availability –
External Specialists and Consultants – change log – lessons learnt log
Implementing Project URS – pFMEA – VP – FAT – SAT – IQ – RI – DOE – OQ – PQ
Supporting Documentation- Cleaning Instructions –
Maintenance Intervals – Packing Instructions – Validation
Protocols – Training – Quality Specification – Spare Parts
Hand over to production
Generating Knowledge
12 Proprietary & Confidential | marnus.dutoit@thermofisher.com | 28-October-2021
IMPACT FROM PROCESS on OPTICAL PROPERTIES and CRITICAL TO FUNCTION
MEASUREMENTS ANALYSIS
Understanding the IVF MD4 Multiwell plate weld line and flatness
Scientific Moulding
Validation Measurement vs. Optical Requirements
Current
Process
Window
Running in focused on critical
parameter’s impact on dimensional
stability of validation measurements
• Holding Pressure
• Holding Pressure Time
• Cooling Time
Dimensional stability of
critical to function
measurements
Impact of injection profile
on optical requirements
Running in not focused on impact of injection
profile on optical requirements
• Injections speed
• Temperature profile manifold
• Temperature profile nozzles
Variable: Impact of part design on mould
filling profile
Phases in selecting process window:
1. Running in
2. Stability Test (LLL – NNN – HHH)
3. DOE (GMP parameter’s impact on
Validation Measurements)
Optical Requirements
Impact of injection profile
on optical requirements
• Baseline study to identify the critical parameters to
include in a DOE for mapping Injection moulding
parameter’s impact on optical quality and defects.
• Critical to function area of the MD4 Part is the four
well bottoms in each plate
Literature Review:
1. Visualization of melt flow lines in injection molding, E. Bociąga, et al. Journal of Achievements in Materials and Manufacturing Engineering, 2006
2. Thin-wall injection moulding of polystyrene parts with coated and uncoated cavities, Davide Masato et al. Journal of Materials and Design, 2017
3. Influence of processing parameters on Injection Molded polystyrene using Taguchi method as DOE, Tan Yizong et al, Journal of Advances in Materia and
Processing Technologies, 2017
4. Optimization of gate location based on weld line in plastic injection moulding, R. Sedighi et al, International Journal of Automotive and Mechanical
Engineering, 2017
Study 1: Baseline study of mould filling
RUN 1: Theoretical study to simulate
weld flow lines
Shot size step interval: 5cm³
Injection speed: 10cm³/s
Temperature profile: 210ºC
Holding pressure: 0
RUN 2: Shot fil pattern at optimal
settings
Shot size step interval: 5cm³
Injection speed 225cm³/s
Temperature profile 230ºC
Holding pressure 0
Run
2
Run
1
Study 2: Baseline of current settings
• No Holding Pressure
Cylinder Temperature
• 230-230-220-210-170-50 °C
Formvarme
• Indløbsbøsning 230°C
• Manifold 235°C
• Dyse – Zone 1 235°C Låg
• Dyse – Zone 2 35°C Låg
• Dyse – Zone 3 245°C Bund
• Dyse – Zone 4 245°C Bund
Køling af form
• Forpart – kreds 1-2 16 °C Direkte koldt vand
• Forpart – kreds 3-10 40 °C
• Bagpart – kreds 11-18 40 °C
• Shot Size: 41cm³
• Injection Speed 225cm³/s
• With Holding Pressure
The weld line/melt line is not an
issue as long as it is on the side of
the well.
STUDY Summery and overlay
Cylinder Temperature
• 230-230- 220-210-170-50 °C
Formvarme
• Indløbsbøsning 230°C
• Manifold 235°C
• Dyse – Zone 1 235°C Låg
• Dyse – Zone 2 35°C Låg
• Dyse – Zone 3 245°C Bund
• Dyse – Zone 4 245°C Bund
Køling af form
• Forpart – kreds 1-2 16 °C Direkte koldt vand
• Forpart – kreds 3-10 40 °C
• Bagpart – kreds 11-18 40 °C
• Shot Size: 41cm³
• Injection Speed 10 and 225cm³/s
Degree of transparency increases in overlay
• Theoretical model indicates that the influence of injection speed,
melt temperature and holding pressure contribute to stresses in well
bottom area
• With incorrect parameter settings there is a risk that defects can
occur in this critical area
• Change over to the holding pressure stage could cause “wall-slip”
due to polymer surface tension and melt flow resistance from the
solidifying melt contribute to the defect in the well bottom
Injection Speed 10cm³/s Injection Speed 225cm³/s
Thank you
18
QUESTIONS?

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Thermo Fischer Scientific - Marnus Du Toit - Plastic Engineering Day 2021

  • 1. Welcome 1 Proprietary & Confidential | marnus.dutoit@thermofisher.com | 28-October-2021 A Day in the life of a Manufacturing Engineer at Thermo Fisher
  • 2. Introducing 2 Proprietary & Confidential | marnus.dutoit@thermofisher.com | 28-October-2021 Marnus du Toit Manufacturing Engineer, Laboratory Plastics Division • ND.: Plastics Technology, Cape Peninsula University of Technology, 2001 • B.Eng.: Global Management and Manufacturing (GMM), Aarhus University, 2014 • M.Sc.: Operations and Management Engineer (OME), Aalborg University ,2018
  • 3. 3 Proprietary & Confidential | marnus.dutoit@thermofisher.com | 28-October-2021
  • 4. 4 Proprietary & Confidential | marnus.dutoit@thermofisher.com | 28-October-2021
  • 5. 5 Proprietary & Confidential | marnus.dutoit@thermofisher.com | 28-October-2021 INJECTION MOULDING MACHINES and AUTOMATED PRODUCTION LINES with 3000TONES OF POLYMER USAGE PER YEAR R&D – QA – QC – SUPPLY CHAIN – PRODUCTION PLANNING AND CONTROL – LEAN AND BUSINESS OPTIMIZATION – FINANCE – VALUE STREAM MANAGEMENT – WAREHOUSE AND LOGISTICS – MAINTENANCE – FACILITY MANAGEMENT – GLOBAL SUPPLY – ACCOUNDTING – ENGINEERING -HEALTH AND SAFETY – BUSINESS INTELLEGENCE – METROLOGY – TECHNICAL DOCUMENTATION – NUNC ATOM 500 EMPOYEES – 3 SHIFTS 24/7 PRODUCTION
  • 6. 6 Proprietary & Confidential | marnus.dutoit@thermofisher.com | 28-October-2021
  • 7. 7 Proprietary & Confidential | marnus.dutoit@thermofisher.com | 28-October-2021
  • 8. 8 Proprietary & Confidential | marnus.dutoit@thermofisher.com | 28-October-2021
  • 9. 9 Proprietary & Confidential | marnus.dutoit@thermofisher.com | 28-October-2021
  • 10. 10 Proprietary & Confidential | marnus.dutoit@thermofisher.com | 28-October-2021 On a STRATIC LEVEL I manage highly skilled, cross functional, internal and external EXPERTS to deliver RESULTS within the TIME available On a TACTICAL LEVEL I run COMPLEX analysis to generate understanding and KNOWLEDGE though a systematic approach On a OPERATIONAL LEVEL I support CRITICAL functions to meet customer EXPECTATIONS
  • 11. 11 Proprietary & Confidential | marnus.dutoit@thermofisher.com | 28-October-2021 Business case formulation – Project Budget Estimation - Payback calculation – Acquisition Request – Purchase Order – Supplier Relationship Management – Economics – Negotiation Project Design Charter and Scope – Timeline – Project Risk Analysis & What If’s – Steering Committee Reports – Resource Availability – External Specialists and Consultants – change log – lessons learnt log Implementing Project URS – pFMEA – VP – FAT – SAT – IQ – RI – DOE – OQ – PQ Supporting Documentation- Cleaning Instructions – Maintenance Intervals – Packing Instructions – Validation Protocols – Training – Quality Specification – Spare Parts Hand over to production
  • 12. Generating Knowledge 12 Proprietary & Confidential | marnus.dutoit@thermofisher.com | 28-October-2021 IMPACT FROM PROCESS on OPTICAL PROPERTIES and CRITICAL TO FUNCTION MEASUREMENTS ANALYSIS Understanding the IVF MD4 Multiwell plate weld line and flatness
  • 13. Scientific Moulding Validation Measurement vs. Optical Requirements Current Process Window Running in focused on critical parameter’s impact on dimensional stability of validation measurements • Holding Pressure • Holding Pressure Time • Cooling Time Dimensional stability of critical to function measurements Impact of injection profile on optical requirements Running in not focused on impact of injection profile on optical requirements • Injections speed • Temperature profile manifold • Temperature profile nozzles Variable: Impact of part design on mould filling profile Phases in selecting process window: 1. Running in 2. Stability Test (LLL – NNN – HHH) 3. DOE (GMP parameter’s impact on Validation Measurements)
  • 14. Optical Requirements Impact of injection profile on optical requirements • Baseline study to identify the critical parameters to include in a DOE for mapping Injection moulding parameter’s impact on optical quality and defects. • Critical to function area of the MD4 Part is the four well bottoms in each plate Literature Review: 1. Visualization of melt flow lines in injection molding, E. Bociąga, et al. Journal of Achievements in Materials and Manufacturing Engineering, 2006 2. Thin-wall injection moulding of polystyrene parts with coated and uncoated cavities, Davide Masato et al. Journal of Materials and Design, 2017 3. Influence of processing parameters on Injection Molded polystyrene using Taguchi method as DOE, Tan Yizong et al, Journal of Advances in Materia and Processing Technologies, 2017 4. Optimization of gate location based on weld line in plastic injection moulding, R. Sedighi et al, International Journal of Automotive and Mechanical Engineering, 2017
  • 15. Study 1: Baseline study of mould filling RUN 1: Theoretical study to simulate weld flow lines Shot size step interval: 5cm³ Injection speed: 10cm³/s Temperature profile: 210ºC Holding pressure: 0 RUN 2: Shot fil pattern at optimal settings Shot size step interval: 5cm³ Injection speed 225cm³/s Temperature profile 230ºC Holding pressure 0 Run 2 Run 1
  • 16. Study 2: Baseline of current settings • No Holding Pressure Cylinder Temperature • 230-230-220-210-170-50 °C Formvarme • Indløbsbøsning 230°C • Manifold 235°C • Dyse – Zone 1 235°C Låg • Dyse – Zone 2 35°C Låg • Dyse – Zone 3 245°C Bund • Dyse – Zone 4 245°C Bund Køling af form • Forpart – kreds 1-2 16 °C Direkte koldt vand • Forpart – kreds 3-10 40 °C • Bagpart – kreds 11-18 40 °C • Shot Size: 41cm³ • Injection Speed 225cm³/s • With Holding Pressure The weld line/melt line is not an issue as long as it is on the side of the well.
  • 17. STUDY Summery and overlay Cylinder Temperature • 230-230- 220-210-170-50 °C Formvarme • Indløbsbøsning 230°C • Manifold 235°C • Dyse – Zone 1 235°C Låg • Dyse – Zone 2 35°C Låg • Dyse – Zone 3 245°C Bund • Dyse – Zone 4 245°C Bund Køling af form • Forpart – kreds 1-2 16 °C Direkte koldt vand • Forpart – kreds 3-10 40 °C • Bagpart – kreds 11-18 40 °C • Shot Size: 41cm³ • Injection Speed 10 and 225cm³/s Degree of transparency increases in overlay • Theoretical model indicates that the influence of injection speed, melt temperature and holding pressure contribute to stresses in well bottom area • With incorrect parameter settings there is a risk that defects can occur in this critical area • Change over to the holding pressure stage could cause “wall-slip” due to polymer surface tension and melt flow resistance from the solidifying melt contribute to the defect in the well bottom Injection Speed 10cm³/s Injection Speed 225cm³/s