FALLO approach

All processes fit into a scheme that requires the interaction and proper control of different operations. An example is the FALLO (Follow ALL Opportunities) approach that 

Tools include dies, molds, mandrel, jigs, fixtures, punch dies, etc. for shaping and fabricating parts (Tables 8-13 and 8-14). 

Molds are used in many plastic processes with many of the molds having common assembly parts (Fig. 8-11). Many molds, particularly for injection molding, have been preengineered as standardized products that can be used to include cavities, different runner systems, cooling lines, unscrewing mechanisms, etc. (Table 3-17). 

Alloy Designation Tensile Strength 0.2% Yield Working Hardness Coeff. of Thermal Expansion Thermal Conductivity Cost Index 

Production molds are usually made from steel for pressure molding that requires heating or cooling channels, strength to resist the forming forces, and/or wear resistance to withstand the wear due to plastic melts, particularly that which has glass and other abrasive fillers. However most blow molds are cast or machined from aluminum, beryllium copper, zinc, or Kirksite due to their fast heat transfer characteristics. But where they require extra performances steel is used. 

Conditions that are important in making plastic products the success it has worldwide are summarized in Fig. 1.15. All designs, processes, and materials fit into this overall FALLO (Follow ALL Opportunities approach flow chart that produces products meeting required performance and cost requirements. 

1 Designing a product to meet performance and manufacturing requirements at the lowest cost  

2 Specifying the proper plastic material that meets product performance requirements after being processed  

4 Purchasing and properly warehousing plastic materials and maintaining equipment. 

Using this type of approach leads to maximizing product s profitability. If processing is to be contracted, ensure that the proper equipment is 

Throughout this book, different subjects are reviewed that pertain to reinforced plastic (RP) products. This chapter provides additional information on RP products and marketing aspects effecting RP products. 

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Designers and processors to produce products at the lowest cost have unconsciously used the basic concept of the FALLO approach. This approach makes one aware that many steps are involved to be successful, all of which must be coordinated and interrelated. It starts with the design that involves specifying the plastic, and specifying the manufacturing process. The specific process (injection, extrusion, blow molding, thermoforming, and so forth) is an important part of the overall scheme and should not be problematic. 

Perfection is never reached there is always room for improvements as summarized in the FALLO approach (Fig. 1-3) and throughout history. As it has been stated, to live is to change and to reach perfection is to have changed often (in the right direction). 

The approach just outlined is after-the-fact approach to QC all defects caught in this manner are already present in the product being processed. This type of QC will usually catch defects and is necessary, but it does little to correct the basic problem(s) in production. One of the problems with add-on QC of this type is that it constitutes one of the least cost-effective ways of obtaining quality products. Quality must be built into a product from the beginning of the design that follows the FALLO approach (Fig. 1-3) it cannot be inspected into the process. The target is to control quality before a product becomes defective. 

While there are many definitions of value analysis, the most basic is the following formula where VA = (function of product)/(cost of the product). Immediately after the product goes into production, the next step that should be considered is to use the value design approach and the FALLO approach (Fig. 1-3). These approaches are to produce products to meet the same performance requirements but produced at a lower cost. 

Figure 1.6 FALLO approach includes going from material to fabricated product (courtesy of Plastics FALLO)...

FALLO approach includes going from material to... 

An example of the complete IM operation is shown in Figure 9. This FALLO approach (Follow ALL Opportunities) summarizes what should be considered to ensure a good return on investment to produce all types and shapes of molded products. These important steps must come together properly to produce products consistently meeting... 

Use FALLO approach. Reevaluate all parameters used from part design (use less plastic), use lower costs plastic with similiar processing costs (or plastic with higher cost-processes faster-results In total lower cost), check hardware performance, S other parameters described in the IM HANDBOOK. 

To understand potential problems and their solutions, it is helpful to consider the relationships of machine capabilities, plastics processing variables, and product performances. A distinction has to be made between machine conditions and processing variables. For example, machine conditions include operating temperature and pressure, mold or die temperature, and machine output rate. Processing variables are more specific, such as the melt condition in the mold or die and the flow rate versus temperature. See FALLO approach morphology polymer, reactive profit and technology. 

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