2013 Technical Conference Program
All sessions, times and presenters are subject to change.
|WEDNESDAY, JUNE 12, 2013|
|8:00 am - 8:15 am | ENGINEER|
Sponsor Keynote (+)Glenn Starkey - Society of Plastics Engineers
Mold Making and Mold Design Division
Engineer Panel Introduction:
Goal: To bring to the forefront the technologies and best practices necessary for the critical decision-making that needs to take place by the mold buyer and mold builder. Topics will include part/mold design, simulation, putting intelligence in the mold, and a look at innovative ways OEMs, molders and moldmakers are working together.
|8:15 am - 9:15 am | ENGINEER > Technology and Training for Improving Your Design Process|
Best Practices for In-Mold Pressure/Temperature Sensors (+)Dan Clark - RJG, Inc.
Engineer Panel 1: Technology and Training for Improving Your Design Process Best Practices for In-Mold Pressure/Temperature Sensors
Dan Clark joined the RJG Team in 2008 as a member of the Consulting and Training Group, covering the Western and Midwestern United States.
Dan has spent the last twenty years in the plastics industry. He worked with RJG equipment as the plant manager for Wise Plastics where he gave instruction on and implemented Decoupled 2 and 3 processes. Dan’s work experience over the past twenty years has included mold set-up, job scheduling, programming robots, the development of training materials, implementation of process standardization practices and employee hiring and training.
He also owned Raycom Enterprise, a company that focused on Lean manufacturing programs. Dan received his plastics degree from Elgin Community College and is a certified RJG Master Molder.
What some of Dan’s students had to say about their training:
“The class was better than expected. Meaning that there was more information about the total process from beginning at steel cutting all the way to the end product.” Kevin Allen/ TAC Manufacturing, Inc.
“This course was very informative and will help me troubleshoot problems and help improve our process.” Jeff Nevel/ Richco, Inc.
“I did not expect to hear a lot of new ideas but I was wrong. I see things that I have been doing for years and this course showed me there is so much more.” Rick Hall/Richco, Inc.
Get a window into what's happening inside the mold with each process by using proper sensing technology. In-mold pressure and temperature sensors can help reduce time and improve continuity, get immediate notification of any process deviation, minimize costs related to manual inspection, reduce scrap , diagnose problems and prevent the shipment of imperfect parts. This session will review of in-mold pressure and temperature instrumentation with a look at some common do's and dont's, best practices for sensor implementation and areas of concern.
Mold Design for the Project Engineer (+)James Michalenko - Thogus
Engineer Panel 1: Technology and Training for Improving Your Design Process Mold Design for the Project Engineer
James Michalenko is the Engineering Manager with Thogus, a custom injection molding and engineering company located in Avon Lake, Ohio. Since joining Thogus, James has been heavily involved in lean manufacturing, process optimization, and program management of new and transfer tooling. Currently, as a key leader at Thogus, James has become the engineering manager who oversees program management, tooling, process engineering, and equipment and facilities maintenance. He has led a team to help further develop automation and technology, as well as orchestrate facility upgrades to improve molding efficiencies. James took engineering to a different level by nurturing the front-end engineering of Thogus in order to improve product launch through advance product quality planning and program management.
James also implemented Thogus’ Co-Op program with Penn State Behrend where Plastic Engineering Technology Students come to Thogus for a hands on experience in operations and engineering. This program is responsible for creating the next generation employee for Thogus as well as the industry.
James is a Plastics Engineering Technology graduate of Penn State Behrend, and has been member of the Manufacturer’s Association of Plastics Processors (MAPP) through Thogus’ affiliation since 2009.
Thogus is not just your ship and shoot molder they have the expertise and technology to work with clients from product development to prototyping all the way through production; therefore, they push forward with continued plastics education—in plastic principles, including plastic flow, types of melt delivery systems, how to size up a mold for a given molding machine, mold cooling design strategies, and common mold design pitfalls, among other topics. This education provides an understanding the mold and its role in part quality as well as the basics of mold design, which helps to ensure molders comprehend the limitations as well as the possibilities in mold design—ultimately improving the moldmaker/molder relationship.
Optimize Your Mold Design (+)Kevin Klotz - MGS Mfg Group
Sr. Project Engineer
Engineer Panel 1: Technology and Training for Improving Your Design Process Optimize Your Mold Design
In today’s global competitive market, every choice made during the product development process must be a careful consideration of materials and processes in order to help ensure the customer’s success and thus ultimately the success of the tool and molding vendor. Every cost-saving opportunity should be evaluated by an experienced development team and implemented if the numbers make a strong case for the opportunity. Going beyond the normal tool building practices to achieve a unique outcome is sound business strategy, but only if the scope of the project and the customer relationship merit the investment. Selecting alternative tool materials and applying new cooling techniques can help reduce cost, improve quality, and achieve a new level of design success for the business willing to accept the challenge of carefully pre-engineering tooling for challenging new part designs. This presentation will highlight how to use comprehensive process simulation to optimize mold design for maximum productivity—focus on conformal cooling channel strategy.
|9:15 am - 9:30 am | ENGINEER|
|9:30 am - 10:15 am | ENGINEER > Mold Technology that Affects Your Customers|
Additive Manufacturing Helps Build a Niche (+)Jason Warr - Linear Mold & Engineering, Inc.
Engineer Panel 2: Mold Technology That Affects Your Customers Additive Manufacturing Helps Build A Niche
As an early adopter of Direct Metal Laser Sintering (DMLS), Linear has developed a niche of building conformal cooling lines to complement its mold manufacturing business. Linear has developed an expertise in the design and build of tooling inserts with conformal cooling channels. With demand from OEMs and Tier 1 and Tier 2 suppliers increasing for reduced cycle times and better quality while controlling costs to manufacture, Linear continues increasing its capacity in DMLS to provide solutions.
Advancement of Molding Efficiencies Through Cyclic Process Thermodynamics (+)Ed Bernard - Crest Mold
Engineer Panel 2: Mold Technology That Affects Your Customers Advancement of Molding Efficiencies Through Cyclic Process Thermodynamics
Ed Bernard is primarily occupied with Research & Development at Crest Mold Technology Inc. while remaining actively involved on several dynamic industry association and nonprofit boards.
The rules for molding plastic parts are drastically changing. Barriers which have restricted part design, product development, mold design, and processing efficiencies can now be overcome. Appropriately the science of Thermodynamics was established to understand and advance the physics of steam energy and now, less than 160 years later, it is being applied to advance the physics of plastic parts production.
These breakthroughs are applicable to petroleum based polymers as well as to hybrids and renewable bio-materials.
Be liberated from the barriers that you can now eliminate, and apply the technology that will increase your profits.
Opening Up a World of Molding Possibilities (+)Alan Petrucci - B A Die Mold
Engineer Panel 2: Mold Technology That Affects Your Customers Opening a World of Possibilities
Alan Petrucci was named the American Mold Builders Assn. Mold Builder of the Year at the group's just-concluded 2011 annual convention. The award was presented my Mike Armbrust, president of the AMBA. Petrucci has spent more than 53 years in the mold building industry beginning by working as a teenager for his father, Henry Petrucci, who owned Mirro-Brite, a mold polishing company. Alan began his apprenticeship as a moldmaker after graduation from high school at age 17.
He joined the AMBA in 1973. B A Die Mold (formerly of Rolling Meadows, IL, and now in Aurora, IL) would have been one of the ‘official’ charter companies of AMBA if Petrucci had not had to work that night to deliver a mold on time. He was instrumental in the founding of the organization along with Ole Bradley of PM Mold, and others. When Alan Petrucci started B A Die Mold Inc. in 1968, he never dreamed that he would become one of the mold manufacturing industry’s most honored businessmen.
Glenn Starkey (left) of Progressive Components presents Mold Builder of the Year Alan Petrucci with a check for $5000. Petrucci is deciding how the funds can go to help young people entering the trade.
Petrucci has been active in the AMBA from the outset, volunteering his time to teach at College of DuPage via the AMBA’s early apprenticeship program and serving on apprenticeship committees. He also served on the Lyons Township High School Board for Vocational Training where he promoted moldmaking as a viable career path and spoke on career days to the students and advised the high school about how to structure its machinist and metalworking programs.
Petrucci has donated his time and resources wherever possible to ensure that all apprentices got a good start in the industry, and he has employed and educated numerous apprentices at B A Die Mold over the years—many of whom now own their own companies as a result. To this day he attends almost every Chicago Chapter meeting.
Petrucci has served the AMBA in many capacities over the years, and was a founding member of the Chicago AMBA’s Save American Manufacturing (SAM) USA organization, which went national and has never ceased in his endeavors to see U.S. manufacturing regain a strong foothold in the global marketplace.
On the shop side, B A Die Mold developed a system that offers precision positioning of virtually unlimited threads on any given part. The Programmable Electric Rotating Core (PERC) can be adapted to both traditional and hydraulic molding machines. PERC was officially patented in 2010 and customers who have utilized the system have only five-star reviews for it.
Other, earlier, firsts for B A include developing hot runner systems for molding starch. This was a proprietary medical application for a pharmaceutical customer that came about following the Tylenol scare back in the late ’80s. The starch capsules were tamper resistant and would shatter if anyone tried to do anything to them. B A didn’t invent the idea, but was the first to make it work.
“Sitting there listening to Mike Armbrust read the bio of the Mold Builder of the Year award winner, I was trying to guess whether or not I knew the person since the years mentioned seemed to match my own,” said Petrucci afterwards. “When it dawned on me it was me he was introducing I was totally dumbstruck. My daughter, Cyndi, had to give me a shove to get me started up to the podium. I was so overwhelmed with emotion realizing that I had been selected out of all the countless other fine shop owners who deserved this, that I couldn’t find words to express my gratitude to the Board of Directors. I did manage to blurt out ‘I love the trade!’ All I could think of was that I’ve been selected to join a very special group of my peers. Thank you!”
Petrucci also received $5000 from Progressive Components, and is considering where to donate the money to benefit the industry. —Clare Goldsberry
A look at how those charged with raising the sales of a mold building company can differentiate their shops from the competition. For example, the development of this mold manufacturer’s Programmable Electric Rotating Cores (PERC) system as a value-added service to its customers. This programmable system that drives the unscrewing mechanism used to rotate cores in an injection mold has many benefits over hydraulic systems—including compactness, programmability, fast and accurate core positioning, and elimination of parts contamination with hydraulic oil. We will also discuss why it is important for moldmakers to be strong innovators in process and technology to better serve their customers.
The Value of In mold Assembly Tooling (+)Michael Schmidt - Zahoransky Formenbau GmbH
Managing Director of Sales
Engineer Panel 2: Mold Technology That Affects Your Customers The Value of In-Mold Assembly Tooling
Designing hotrunner systems
Product Development Manager 1997 to 2000
Sales since 2001
Sales Manager since 2004
Vice President Sales since 2008
Managing Director Sales since 2011
The session will highlight the latest developments of the TIM (Total Integrated Manufacturing) concept for multi-component molding and in-mold assembly using four-sided turning stacks and external reciprocating/rotating plates that interact with the exposed sides of the tool during the molding cycle. TIM systems can mold and assemble two or more parts in 6 sec. The presentation will include the sequence of operation, benefits and applications of the TIM concept as well as a number of variants and elaborations.
|10:15 am - 11:15 am | ENGINEER > Innovative Ways OEMs, Molders and Mold Builders Are Working Together|
Becoming a Go-To Business Partner to Top Molders (+)Tim Stewart - Donnelly Custom Manufacturing Company
Engineer Panel: 3 Innovative Ways OEMs, Molders and Mold Builders are Working Together Becoming a Go-To Business Partner to Top Molders
With responsibilities in sales and new customer project management, Tim works to coordinate the efforts of Donnelly's sales team, helping to seek and serve customers that are a good fit for the Donnelly business model. Tim's experience and education in both business and engineering enables him to understand and communicate with customers on a wide range of issues—from operations and engineering to manufacturing – and on the importance of the engineering function throughout the supply chain to most effectively minimize tooling and product costs while optimizing output value during the development stage
What’s the best way to set yourself apart as a tooling supplier? How do you build a relationship with the right kind of molder for your business? First, you need to fully understand what today’s customer is looking for. In this presentation, we’ll explore the criteria for evaluating and partnering with moldmakers used by one particularly discerning injection molder – Donnelly Custom Manufacturing Company, a specialist in short-run custom molding and related engineering & manufacturing services based in Alexandria, MN. Launching more than 200 molds per year has made selecting the right mold supplier mission critical to Donnelly’s ongoing success. Tim Stewart, Donnelly’s Business Development Manager, will share insights into the company’s refined process for seeking out suppliers whose business model and values align closely with Donnelly’s. His unique insider’s take will provide powerful information on the creativity, collaboration, niche expertise and other keys to becoming a go-to business partner to top molders across the country.
Evolving Relationship Between Mold Builder and Mold Buyer (+)Doreen Lettau - Dickten Masch Plastics
VP of Market and Business Development
Engineer Panel: 3 Innovative Ways OEMs, Molders and Mold Builders are Working Together Evolving Relationship Between Muld Builder and Mold Buyer
A changing economic landscape often means shifting your business model to adapt to both new challenges and new opportunities. For molders, things like globalization, shrinking lead times and a broadening skills gap have led to the evolution of the relationship between the mold builder and the mold buyer. Whereas before it was quite common for processors to build molds in-house, in this session, Lettau will speak to the shift that molder Dickten Masch Plastics (DMP) has experienced to a mostly partnership driven model, where each party focuses on what they do best vs. trying to do it all. This model doesn’t mean that mold making expertise is limited to only one side of the equation, however. Reality is that molders still need to know just as much about tool designs and builds as their counterparts, ensuring smooth start-ups and minimal production interruptions. Lettau explains that it’s for this reason that DMP maintains a tooling center with technical competencies, 24/7 service to the manufacturing facility, preventative maintenance and predictive maintenance. Attendees with hear one molders success with this new model and how its many mold making partners, and ultimately customers, are all benefitting in the end.
Tooling Vendor Selection Guide (+)Gary J. Kieffer - Currier Plastics
VP of New Product Development
Engineer Panel: 3 Innovative Ways OEMs, Molders and Mold Builders are Working Together Tooling Vendor Selection Guide
With mold design and quality an essential component of any successful mold program, searching for the right tooling vendor is a methodical process. This presentation will look at how Currier Plastics has cultivated a strong group of both domestic and international partners with whom it works to offer customers the best in leadtimes and costs. While the quality and cost of both blow-molded and injection-molded products depend on a variety of factors, the design and quality of the tooling or molds is a prime factor in the scope of any successful program. Currier’s designers and engineers work hand-in-hand with each of their selected partners when building its custom molds. The communication between the Currier Plastics team and its mold builders uses the most modern advances in CAD/CAM systems to produce our innovative blow-molded packaging and high-tech injection mold designs.
|11:15 am - 12:00 pm | ENGINEER|