Plastic Injection Molds & Molding » paul

Design Review Conferencing

paul — Thu, 17 Jun 2010 13:08:42 +0000

Since we’ve added web conferencing several years ago, it becomes more and more evident how this tool significantly improves the design / build process as costs are scrutinized and deliveries compressed. One recent program stands out, a stapling device with numerous metal and plastic parts that were activated by a series of gears and pulleys. Our initial design review with the customer using our web conferencing program allowed us to review the entire assembly get an overview of the device with a diverse group of Matrix personnel. Representatives from our design, manufacturing and quality areas all reviewed the device from their own point of view. And with the convenience of a voip phone call, our marketing manager attended the meeting remotely. During the review, suggestions were made to the customer that allowed them to eliminate several parts by redesign of the current assembly. Parts were combined, reducing the part count in the assembly. Slightly more complicated tooling, but far less costly in the long run. The customer immediately embraced those suggestions, as their COGS target for the device was going to be difficult to achieve. The savings our suggestions allowed gave them an immediate benefit. And, during the review, a fundamental design flaw was flushed out when this group of a dozen technical people got into a spirited discussion on the mechanics of the device, which was corrected within days. And as our mold design work was firming up, we held a concurrent review of both tool and product design, which saved significant time. Mold design (ours) and device design (theirs) were being toggled back and forth, with mods to both being made as the meeting continued. A very fast and productive use of time, for sure.

- Paul Ziegenhorn

Transfer Tooling Programs: Streamlining Existing Molding Projects

paul — Wed, 13 May 2009 13:22:00 +0000

Several years ago, a customer we had limited dealings with contacted us to help supply product that was arriving sporadically from their off-shore partner. Numerous quality issues with the molded parts caused a high scrap rate, and the lure of low cost tooling and production wore thin when product was regularly delayed entering the USA. Matrix quickly built low-cavity tooling to keep a stream of parts flowing, allowing time for the transfer of six tools to the States. Once the tools arrived, the molds were disassembled, damage was repaired and mold modifications were performed to enhance their performance. For the next two years, we ran production using the refurbished off-shore tools. In the meantime, customer demand was increasing and production was ramping up so high-cavitation hot runner tooling proposals were submitted. Part of our proposal to the customer was financial justification calculations, including amortizing a portion of the tool cost into each part. Payback to the customer was rapid, in most cases less than 15 months, and with the faster hot runner tools, part prices dropped dramatically. In addition, quality problems went away, and with Matrix covering the tool maintenance for the life of the program, the cost to the customer was predictable and affordable. For more information on our transfer tooling capabilities please visit our main website.

Written By:

Paul Ziegenhorn
President

Job Losses in Manufacturing

paul — Fri, 14 Nov 2008 16:22:00 +0000

Much is published about currency manipulation, unfair trading practices, and low cost offshore labor as primary reasons for the large loss of high paying manufacturing jobs in the USA. One thing rarely mentioned is the concept that the introduction of computer controlled machines and automation have had a significant impact on USA companies need for manual labor. Requirements for labor today are far different than in days past as manufacturers now need higher skilled people, but less of them. Special interest groups often look for easy targets when determining the reasons for job losses, but the bottom line is that in many cases, companies need fewer people to do the same amount of work as before. And as labor costs continue to climb, it’s the first place a manufacturer will look to reduce his overhead expenses.

Paul Ziegenhorn
President

Lack of Apprentice Training

paul — Fri, 16 May 2008 13:58:00 +0000

I’ve been involved in high school career education programs for much of the last 15 years. A good portion of that time was spent talking to educators and parents about careers in precision manufacturing being a viable alternative to the typical 4-year college program being pushed on our kids. Colleges have done a very good job of convincing us (and especially the parents) that the only way to a successful and rewarding career is to get a degree. I, for one, don’t agree. An apprenticeship can offer a young person another option; and the fact is that college is not necessarily the best choice for many high school students. Most teachers will agree with this logic. They know first hand which of their students are good candidates for advanced degrees and which are more likely to struggle. Most apprentice programs are struggling to attract talented young people, who by that time have had 12+ years of people telling them that they will need to get a degree in order to get a good job.

I know that the U.S. is not the only country with this problem. Much of Western Europe suffers from the same shortages. Many look down on those who work with their hands, but eventually, someone will need to learn and become the next batch of journeyman plumbers, electricians, toolmakers, etc. If not, homeowners better get ready to learn these skills or be ready to open up the checkbook.

I read an interesting article back in the mid 1990’s. In Germany (where an apprenticeship in a trade is still considered a viable career choice), the graduating number of architects outnumbered the number of apprentices from all skilled building trades combined. Think of how many architects it takes to build a home versus the number of workers needed from the various trades, and you’ll realize that something is seriously out of whack. Apparently the Germans, too, have spread the word that working behind a desk versus working with your hands is the way to go.

Hitting closer to home, we’ve struggled with finding quality candidates. Toolmakers today require skills far different than what was needed prior to the computer age, and the fact that few are training today makes for an unsustainable labor situation.

Written by:

Paul Ziegenhorn
President