Welcome to Hybarger Consulting

Krauss Maffei

Hybarger Consulting specializes in cost and quality improvements for Six Sigma & continuous improvement projects by utilizing quality and engineering tools based on twenty years of hands-on manufacturing experience. Results of over three hundred designed experiments for injection molding, screen printing, heat sealing, adhesives, ultra sonic welding, pad printing, assembly components and methods, lamination, forming, and cavity pressure have been successfully implemented. For a complete list of services see below:

General Manufacturing
   • Designed Experiment Review - Email DOE and raw data      files for expert review
   • Analysis of Variance
   • Designed Experiments
   • Response Surface Methodology
   • Evolutionary Operation
   • Process Optimization
   • Process Tolerancing
   • Statistical Process Control
   • Control Plans
   • Failure Mode Effects Analysis
   • Measurement System Analysis
   • Cell Layout
   • Line Balancing
   • Cycle Time Reduction
   • Gage and Fixture Design
   • Cognex Insight Vision System Programming

Arburg

 

 

 

 

 

 

Injection Molding Specific
   • Injection Molding Troubleshooting
   • Pad Print Troubleshooting
   • Ultrasonic Welding Troubleshooting
   • Cavity Pressure monitoring and Control

ITW Transtech

Problem Solving
I have over twenty years of experience in problem solving injection molding, ultrasonic welding, pad printing and assembly operations. During that time I supported several business units and many of the challenging programs and processes that added value for our customers. The products were primarily for automotive, consumer electronics and medical molding and assembly.

 

 

 

Stat-Ease Inc.

Designed Experiments
Analysis of Variance and Response Surface Methodology. All three are powerful statistical tools for any continuous improvement program, process validation or Six Sigma project. Changes are made to factors in a predefined method. Outputs are recorded, such as key product characteristics and analyzed. Unimportant factors can be quickly weeded out. Previously unknown interactions between factors can be found that further improve quality and reduce costs.

Process Optimization
With the use of statistical tools I can determine process settings that target nominal dimensions for key product characteristics and reduce dimensional variability. This improves capability, reduces cost through reject reduction and makes you more profitable.

Norstech Plastics Equipment

Process Tolerancing
During the same trials run during Process Optimization, process outputs can be documented and analyzed. Outputs can then be correlated to key product characteristics for sorting with robotics, conveyors, etc if an out of control condition should emerge. For process validations this means a documented process window supported by statistical data.

Cavity Pressure Control and Monitoring
The ability to sense what is going on inside the mold cavity is one key to being a world class injection molder. No tool is more powerful to a plastics process engineer than mold cavity pressure monitoring. Real time information allows for quick and easy identification of problems. Combine this with designed experiments for setting "real" tolerances based on critical part characteristics to sort defective product. No more guessing about your product quality.

Cognex Corporations

Vision System Programming
The last six years I've programmed Cognex Insight systems. Programs ranged from simple part presence to fully automated cells, where class "A" surfaces were inspected for flaws, character verification, 2D code reading, graphic registration and concentricity.