The injection molding process can seem complex with countless adjustments that will determine whether a process can produce an acceptable part. Organizations are struggling to find and train technical staff with the ability to problem solve. This workshop will aim to help organizations and their staff understand how to effectively resolve issues in the injection molding process. The benefits of effective and methodical troubleshooting can include reduced downtime, increased efficiency, reduced scrap and nonconformances, and improved quality. The workshop will focus on troubleshooting in two primary areas of the injection molding process. The first being the new mold build. Defining and addressing potential issues before a mold is released into production can lead to an efficient and successful tool launch. Using strategic tools, like process development and design of experiments, can determine what outputs achieve critical to quality criteria. The second focus will concentrate on the production aspect of the molding process. These are issues that arise on molds and processes that are already in production. Here we will focus on the 5 M’s (Man, Material, Mold, Method, and Machine) of troubleshooting which will help rectify downtime and defects. This strategic approach will teach staff how to identify the root cause quickly, establish a fix for the issue, and create preventative measures so the problems no longer arise.

Process engineers responsible for designing and optimizing injection molding processes who want to enhance troubleshooting skills. Professionals responsible for the maintenance and repair of injection molding machines and molds, seeking in-depth knowledge to diagnose and resolve issues efficiently.

Production managers overseeing injection molding operations who want to improve overall efficiency and reduce downtime by addressing problems promptly.

Quality control professionals focused on injection molded products, where troubleshooting skills are essential for maintaining product quality and consistency.

Individuals working in the broader plastics industry who want to deepen their understanding of injection molding processes and troubleshooting techniques.

• Do you find yourself constantly adjusting process parameters, yet struggling to produce consistent, high-quality molded parts?
• Are you dealing with frequent machine downtime, excessive scrap, or customer complaints that damage your reputation and profitability?
• Do you want to gain the skills needed to identify root causes faster, fix problems efficiently, and prevent them from recurring?

If the answer is YES to any of these questions, this workshop is for you.

Everyday Problems You’ll Address:

• Why do injection molding processes often produce inconsistent parts, even under the same setup?
• How can I reduce downtime and eliminate costly defects or non-conformances?
• What can I do to detect and solve issues before a new mold even reaches production?
• How can I use tools like Design of Experiments (DOE) to improve part quality and process capability?
• What’s the best way to troubleshoot recurring problems in running molds using the 5 M’s (Man, Material, Mold, Method, and Machine) framework?
• How do I train my team to think systematically and make data-driven adjustments instead of trial-and-error guesses?

Why This Workshop Matters:

Injection molding is one of the most powerful manufacturing processes—but also one of the most complex. A single variable can mean the difference between a perfect part and a costly reject.

This workshop gives you a structured, proven approach to troubleshooting at every stage of the molding process—from new tool launches to ongoing production. By mastering these methods, you’ll not only improve consistency and efficiency—you’ll help your organization deliver better products, faster, with fewer defects and less waste.