Nypro Learning Institute

Learning and development are at the heart of the most agile and competitive organizations. The Nypro Learning Institute empowers employees, customers and suppliers to utilize the most advanced plastics and related manufacturing techniques in the world.

Nypro is uniquely qualified to offer a state-of-the-art curriculum in injection molding and related disciplines, which require highly specialized skills and continuous improvement.

Through live and virtual classrooms, and online resources, students:

  • Stay up-to-date on the latest molding and electronics manufacturing technologies and processes
  • Drive quality process and output improvements


And companies can:

  • Enhance plastics solutions for improved customer satisfaction
  • Gain competitive advantages in all operational facets
  • Speed time-to-market, improve quality and lower costs
  • Optimize employee morale by committing to professional development

Courses

Courses are operated in partnership with the Fitchburg State University, Mount Wachusset Community College, RJG Inc., and other corporate and academic partners. Localized classrooms with state-of-the-art equipment and virtual classrooms are available.  Students can attend certain programs and receive certifications virtually anywhere and anytime.

Choose from an array of offerings, including:

Classroom

Master Molder 1

Approximately twice per quarter

This 10-day certificate course focuses on the best practices of process development, documentation and duplication that should be used on any mold in any machine in any location to support the Lean Six Sigma initiatives. This is not necessarily so you can “run machines” but is the best way to achieve the required level of understanding for all those involved in the tasks or the management of injection molding. How to build the best process in the least amount of time, and evaluate the process and processor. Each day involves some participative class room time, daily quizzes, and hands on time with the molds and machines. There are 10 hours of final exams during the last 2 days to confirm the effective transfer of the critical knowledge and skills of Part Design, Molds, Materials, Equipment and DeCoupledSM 2 Processing. A good understanding of shop math is required.

Pricing (includes the books, tests, breakfast and lunch each day):
Nypro/Jabil employee: $3,650
Non-Nypro/Jabil employee: $4,150 (this includes customers and key partners, but not custom molders).

Master Molder 2

Approximately once per quarter

This 10-day certificate course focuses on the use of cavity pressure to reduce the effect of normal variation on the parts caused by the material. This is truly Lean Six Sigma molding. Each day involves some participative class room time, daily quizzes, and time hands on time with the molds and machines. The lab time allows you to experience the improved process control cavity pressure can provide first hand as well as some standard procedures for molding machine evaluations. There are 10 hours of final exams during the last 2 days to confirm the effective transfer of the critical knowledge and skills of Part Design, Molds, Materials, Equipment and DeCoupledSM 3 Processing. Master Molder 1 certificate is required.

Pricing (includes the books, tests, breakfast and lunch each day):
Nypro/Jabil employee: $4,050
Non-Nypro/Jabil employee: $4,550 (this includes customers and key partners, but not custom molders)

Successful Strategies for New Tool Launches

Approximately twice per year

This 3-day course is designed to bring the design, tooling and processing worlds together. You will learn the key points of part design, mold design, cooling, materials, equipment, process development and mold tryouts so that all aspects work together in a Designed for Manufacturability success. This is for all those involved in the tasks or the management of injection molding programs. Examples of process planning are discussed to help the teams objectively evaluate each aspect and prevent the age old “Is it the steel or the process?” conflicts. Each day is primarily participative class room time with some relevant demonstrations at the molding machines. A good understanding of shop math is required.

Pricing (includes the books, tests, breakfast and lunch each day):
Nypro/Jabil employee: $1,300
Non-Nypro/Jabil employee: $2,015 (this includes customers and key partners, but not custom molders)

Design of Experiments for Injection Molding

Approximately twice per year

This 3-day course includes working in teams to actually build a DeCoupled process, design the experiment (the right way), run the samples, measure the parts, enter the data into Minitab, and review the results.

The injection molding process does not comply well the standard DOE type rules very well at all. For example, randomizing the trials is not practical when ever temperatures are used as a factor. Also changing one parameter/factor on the injection molding machine affects many things and can violate our fundamental processing rules. Everything becomes an interaction.

Most often people use a DOE type study to find what parameters to use to “make the right size part”. Often this results in a “bad” process which does not comply with the DeCoupled Molding rules and is not as stable. DOE should not be used to develop a process. It should only be used on a fully capable process and never sacrificing the Six Sigma (DeCoupled) methodology.

There are two ideal ways to qualify for the course, but exceptions have been made.

  1. You are a certified Master Molder 1 with some DOE and Minitab experience.
  2. You are a certified Black Belt and have passed a RJG DeCoupled Molding course such as; Systematic Molding, Systematic Molding for Tooling Engineers, Strategies for Successful New Tool Transfers, or Master Molder 1.

Pricing (includes the books, tests, breakfast and lunch each day):
Nypro/Jabil employee: $2,100
Non-Nypro/Jabil employee: $2,415 (this includes customers and key partners, but not custom molders)

Systematic Molding

Systematic Molding is a three-day foundational course for anyone who wants to develop a systematic approach to molding. Through a combination of classroom instruction and activity-driven learning, students leave with a better understanding of how to develop a machine-independent process, how to make data-driven improvements to existing processes, and how to effectively troubleshoot using scientific and systematic approaches.

Students will also understand the cause and effect relationships between the machine, process, mold, and material as well as how and why polymer behavior is influenced. This will allow them to make informed decisions for lasting solutions instead of band-aid fixes to the process.

This course is a great way to help students be successful in Master Molder!

Course Highlights

  • Mold and part design considerations
  • The four plastic variables of injection molding
  • The molding system
  • The molding problem, simply stated
  • Process control from the plastic’s point of view
  • Introduction to instrumentation strategies

Pricing (includes the books, tests, breakfast and lunch each day):
Nypro/Jabil employee: $1,300
Non-Nypro/Jabil employee: $1,495 (this includes customers and key partners, but not custom molders)

Injection Molding Essentials

This 2-day course is designed for anyone new to injection molding. It provides a solid foundation for understanding the injection molding process and the critical practice of good production techniques. Participants will fully grasp the elements and variables involved in the injection molding process and learn key terminology that will help them communicate and solve molding problems.

Students leave this course familiar with all major components of an injection molding machine and mold, as well as the three elements of the cycle and what happens during each phase. They will understand the general nature and properties of plastics, the economic impact of making rejects, blocking cavities, and cycle time variation, and the importance of the plastic variables (melt temperature, flow rate, pressure gradient, cooling rate, and time) when troubleshooting a process.

Course Highlights

  • Nature and properties of plastics
  • Basic injection molding
  • The clamp, injection unit, and mold
  • Elements of the cycle
  • Molding for quality
  • Avoiding common molding problems
 

Pricing (includes the books, tests, and a lunch each day):
Nypro/Jabil employee: $675
Non-Nypro/Jabil employee: $785 (this includes customers and key partners, but not custom molders)

Part Design for Injection Molding

This 3-day course provides molders, tool makers, and design engineers with a common language and the universal knowledge required to successfully design and produce plastic injection molded components. Improving general knowledge of the steps required for part design reduces the risk of less than optimum tooling conditions, therefore minimizing exposure to injection molding non-conformities that do not meet the quality requirements of the customer.

Class topics address good manufacturing processes (GMP) for: plastic part design, fundamental material characteristics, basic tooling concepts, necessary processing characteristics, molding non-conformities, and tolerances. The course also discusses how part design and material selection affect the cost of tooling and piece price. During training, we utilize industry examples as reference, then dive into evaluating and improving designs. Attendees will work in groups to examine parts to identify where non-conformities will occur and methods to improve those risks.

Course Highlights:

  • Part design – Wall Thickness, Flow Length, Features, Radius, Draft, Gloss
  • Material – Thermoplastics or Thermosets, Melt Flow Index (MFI), Shrink Rate
  • Tooling – Steel, Line of Draw, Actions, Melt Delivery, Ejection, Surface Finish
  • Machine – Clamp Tonnage, Injection Volume, Injection Flow Rate, Injection Plastic Pressure
  • Processing – Melt Temperature, Flow Rate, Pressure Gradient, Cooling Rate & Time
  • Non-Conformities, Warp, Short Shots, Sinks, Voids, Bubbles, Jetting, Blush, Gloss, Knit Lines
  • Tolerance – First Article Inspection, Critical, In-Process
  • Design for manufacturability (DFM) – Part Design Checklist, FMEA

Pricing (includes the books, tests, breakfast and lunch each day):
Nypro/Jabil employee: $1,800
Non-Nypro/Jabil employee: $2,045 (this includes customers and key partners, but not custom molders)

Mold Design for Injection Molding

This 3-day course provides mold makers, design engineers, and molders with the common language and core knowledge required to successfully design robust injection molds that meet cycle time, cost, part quality, and lead time requirements.

Class topics address good manufacturing practices (GMP) for part design, including fundamental material characteristics, necessary processing techniques, and molding non-conformities, with a focus on robust mold design.

As hands-on-learning is a core component of our training, we will utilize industry examples as a reference, and then dive directly into evaluating and improving your designs.

Course Highlights:

  • Part Design – Wall Thickness, Draft, Radius, Undercuts, Surface Finish
  • Prints – Tolerance, Datum’s
  • Material – Melt Flow Index (MFI), Shrink Rate, Heat Deflection Temperature
  • Machine – Clamp Unit, Injection Unit
  • Processing – Melt Temperature, Flow Rate, Pressure Gradient, Cooling Rate and Time
  • Mold - Line of Draw, Steel, Coatings, Actions, Gating, Venting, Support Pillars, Cooling, Ejection, Instrumentation
  • Molding Non-Conformities – Warp, Short Shots, Sinks, Voids
  • Design for Manufacturability (DFM) – Simulation, Mold Design Checklist

Pricing (includes the books, tests, breakfast and lunch each day):
Nypro/Jabil employee: $1,800
Non-Nypro/Jabil employee: $2,045 (this includes customers and key partners, but not custom molders)

 

For course schedules, availability and registration information, please download the Master Molder Schedule.

 

Request a Seat

Online

Basic Injection Molding

This course provides the foundation for understanding the plastics injection molding manufacturing process. Students will learn about the reciprocating screw injection molding machine, molding cycle, the basic components of an injection molding machine, melt flow theory, materials and basic troubleshooting and process effects are examined. The student will have hands–on laboratory experience and will be responsible for a class presentation.

Target: All those involved in the tasks or the management of injection molding programs.

Introduction to Mold Design

This course examines the interrelation of plastics material processing, product designand function, mold design and construction. Fundamental principles of cavity design, material feed systems, ejection systems, parting surfaces, mold actions, cavity and core steel selections. Also, the three-plate molds, insulated runner, and hot runner molds are discussed.

Target: All those involved in the tasks or the management of injection molding programs.

Polymeric Materials Design & Application

This course examines the interrelation of plastics material processing, product designand function, mold design and construction. Fundamental principles of cavity design, material feed systems, ejection systems, parting surfaces, mold actions, cavity and core steel selections. Also, the three-plate molds, insulated runner, and hot runner molds are discussed.

Target: All those involved in the tasks or the management of injection molding programs.

Blueprint Reading

This course introduces the basic concepts of blueprint reading and discusses types of lines, angles, and views of a drawing. The student also learns about dimensioning circles, arcs, holes, and threads. Emphasis is on understanding how to interpret a blueprint. Time permitting; students will learn how to draw a blueprint.

Target: All those involved in the tasks or the management of injection molding programs.

Hydraulics & Pneumatics

This course covers a theoretical and practical study of hydraulics and pneumatics: the modern means of power transmission. This course surveys component design and function with an emphasis on problem definitions and solutions. Following an introduction to hydraulics and pneumatics, students will be exposed to valves, pumps, circuits and hydraulic system troubleshooting.

Target: All those involved in the tasks or the management of injection molding programs.

Industrial Electrical Maintenance

This course covers the concepts of electrical trouble-shooting of injection molding machines and associated equipment. Familiarization with basic electricity symbols, blueprint reading, meters used for trouble-shooting, conventional and solid ladder diagrams/schematics, and trouble-shooting is stressed. Programmable Logic Controls (PLC) is examined.

Target: All those involved in the tasks or the management of injection molding programs.

Principles of Supervision

The purpose of this course is to develop an understanding of the role and responsibilities of the supervisor and to strengthen values and skills related to key supervisory functions. The principles and topics addressed include problem solving, decision making, leadership, management ethics, and communication. This course is recommended for experienced and new supervisors and those aspiring to supervisory positions.

Target: All those involved in the tasks or the management of injection molding programs.

Statistical Process Control

The student will learn the use of statistical methods and SPC to improve quality and productivity through measurement, control, and reduction of variation. Topics covered include: basic statistics, the normal distribution, control charting, process capability studies and gage and measurement analysis. Simple metrology concepts and the basics of geometric dimensioning & tolerance are also discussed.

Target: All those involved in the tasks or the management of injection molding programs.

About the Nypro Learning Institute

For more than 60 years, Nypro has been a leader in driving solution development for packaging and healthcare customers. Recognizing that human capital is our most valuable asset, the Nypro Learning Institute was launched in 1979 to lead corporate learning initiatives in plastics and related manufacturing. We’ve helped more than 2,000 students develop, maintain and extend the skills needed to deliver top performance to their companies and customers.