An innovative manufacturing process for bamboo injection molding by using TRIZ and Taguchi method

Abstract

The appearance of 3C (computer, communication, consumer electronic) electronic products has been considered as a critical attribute to attract consumers in the past decade. Moreover, 3C electronic enterprises with own brands are trying hard to meet the requirements such as user-friendly interface and eco-environmental materials for increasing the revenue and market share. Bamboo had been known as a flexible and green raw-material worldwide for many years. However, there are no bamboo-made applications in any 3C electronic products due to its manufacturing process to achieve satisfactory specifications. The innovative manufacturing process of bamboo injection molding on the appearance of a 3C product suffered from a crucial quality issue, that is, bamboo deformation due to the difference between shrinkage of plastic and its inherent material characteristics. The concept is similar to IMR (in-mold decoration by roller) process. The objective of this article is to propose an innovative and robust bamboo injection molding process by using skills such as measurement system analysis, the Taguchi method, process capability index, and TRIZ. In this study, the detailed experimental process and satisfactory result are demonstrated and given. The exploited approach concerning bamboo is a valuable outcome and reference for further advanced implementations in electrical industry and others.

3C 消費性電子產品的外觀是一個關鍵的屬性吸引著消費者。 因此 ， 3C 的品牌公司都不斷的改善人機介面與尋求新的環保材質來進行產品外觀的設計進而達到增加公司利潤與市場佔有率。 竹皮環保材質的應用在全世界已經使用了很多年 ， 然而各品牌公司卻沒有辦法將其成功應用在消費性電子產品上。 目前業界嘗試透過膜內成型技術將竹皮應用在消費性電子產品外觀上 ， 但卻遭遇到無法克服的變形度問題 ， 其問題來自於竹皮與塑膠縮水率的不同所導致。 本研究將導入量測系統分析法、 田口實驗計畫法、 製程能力分析法與創意思考解決..等方法論 ， 建構出一個創新的研發流程來研發竹皮膜內射出成型技術。 其結果顯示 ， 創新的研發流程成功的解決變形度的品質問題 ， 更能使竹皮膜內射出成型技術具備量產性 ， 進而滿足產品品質相關需求。 而本研究之創新流程標準化更可提供給產業界處裡不同的品質問題時作為相關參考的依據。

(*聯絡人: [email protected])

Keywords:

• bamboo injection molding
• measurement system analysis
• Taguchi method
• TRIZ
• process capability index

Keywords:

• 關鍵詞:竹皮膜內射出成型;量測系統分析法;田口實驗計畫法;創意思考解決法;製程能力分析法

Acknowledgements

The TRIZ-based solutions proposed by this research were applied to the patents at the United States, Taiwan, and Mainland China: Taiwan Patent (no. 098135215), Mainland China Patent (no. 200910180849.0), and the United States Patent (no. 12/906,749).

Notes

(*聯絡人: [email protected])