Waste Management
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Getting It Right First Time

The first consideration in our drive to have the lightest environmental footprint is to “Get it Right First Time” through process mapping and training, ensuring cost are controlled, waste is kept to a minimum and production planning is not compromised. “We do what we say we do, and we do it well”.

 

At Nordell we work with approved, specialist raw material and component suppliers. We purchase materials “just in time” and based on your forecasted demand. Our IQMS Delmiaworks ERP system in conjunction with our buyers and planners ensures we never overstock materials, potentially resulting in waste. Our materials are stored in dedicated warehouse zones and easily accessed through barcoded locations on our ERP.

 

Our team of skilled setters understand the importance of getting into production quickly, reducing the initial startup scrap. Master part setting instructions are stored electronically ensuring all parts have their own, individual setting criteria. Of course, the skill of our setters is to make minor adjustments, taking into account variables such as temperature that may have an impact on standard settings. We maintain an archive of “runs best” moulding machines and our planning team plan production on the same machine, reducing as many variable factors as possible.

 

Setting experience is essential in reducing the possibility of higher levels of waste. At Nordell we continuously invest in our teams and have a Setter and Technician Development Programme providing in house training and assessments. Once our setters have achieved the required standard, we invest in external certified academic training. A number of our experienced setting technicians have now successfully completed their IMT3 training at Polymer Training and Innovation Centre (PTIC) in Telford.

Sustainable Waste Management

Just over a third of Nordell’s injection moulding machines have been replaced with the latest Electric models. Electric moulding machines can reduce energy consumption by 60-80% compared to older hydraulic machines, not only having an environmental benefit, but a relatively quick ROI.

 

Consistency and repeatability of production ensures a very high level of good parts and a low level of scrap. Throughout the production cycle, parts are continuously monitored by our quality inspectors. Our Realtime ERP system ensures all patrol inspections are carried out at specified times throughout the production run, including the sign off of the “first off” and “last off”. Should there be any concerns during production, our machine operators will immediately suspend production with the machines traffic light turning red, alerting the quality inspector and setter, who will assess and the situation and agree a resolution, which may just be some minor setting tweaks.

 

All of Nordell moulding machines are monitored in Realtime allowing the production team to monitor OEE (Overall Equipment Effectiveness).  OEE is the standard for measuring manufacturing productivity and the percentage of manufacturing time that is truly productive.

 

OEE is calculated based on the three OEE Factors: Availability, Performance, and Quality.

  • Availability: The actual number of machines running versus the number of machines planned to run.
  • Performance: The actual cycle Time versus the estimated cycle time.
  • Quality: The actual scrap/part waste versus the estimated scrap levels

 

How we calculate OEE

 

Waste and scrap levels are monitored throughout the production run with action taken to address any waste levels that deviate from the estimated scrap performance. There will always be some waste in the production cycle, however keeping it to a minimum is essential in ensuring our environmental impact is minimal.

 

Prior to any production run, key stakeholders from all operational departments meet to review the upcoming production in a pre-production meeting where any previous waste or reported issues will be highlighted. If the part has been previously flagged, it will be subject to very close monitoring during the production run.

 

Most of our production parts are made from virgin materials in line with our customers specifications although we can offer recycled materials where a part specification will allow.

 

It is impossible to reduce all waste from the moulding process. All waste parts and sprue waste is separated by material type for collection by commercial plastic recyclers. Some of our plastic waste is reground on site where there is a demand.

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