The Challenge

As part of the FLEXAN LLC family of medical device manufacturing companies, MEDRON specializes in product development, design for manufacturability, and production of thermoplastic molded and extruded components. Our customers are in the top 100 of medical device OEMs worldwide. Over the years, we have supported a wide variety of projects for our customers. During a recent project, we faced molding inconsistencies due to resin variability from lot to lot. We also wanted to optimize our insert molding process and maximize throughput of automatic injection molding processes. We had explored operator training, requiring tighter resin specifications, changing mold designs, and more. Some of these items improved results, but not to the extent we were looking for.

The Solution

We first heard about RJG from other colleagues in the injection molding industry and decided to start working with them in 2013. After our engineers completed the RJG Systematic Molding training, we decided to implement Decoupled II molding techniques in process validations for new products. We opted for RJG’s training because it was highly recommended by others who had completed it. It was a good fit for us because it was on-site, only one week, and the trainer was very knowledgeable. We were able to participate in several demonstrations and activities, which made it more interactive and memorable.

The Result

Our first indication of increased quality and cost savings was the significant increase in throughput. We are now able to make more than twice as many parts in the same amount of time—one process part output increased from 16,000 to 40,000 parts per day. Our scrap rates have also decreased significantly since implementation. We now have a more robust injection molding process that is less sensitive to resin lot to lot variability thanks to Decoupled II molding. We are interested in learning about the benefits of other RJG equipment and will evaluate a plan for implementation. RJG products and training provides our customers with better on-time delivery, better part quality and consistency, and allows us to better meet product growth needs.

Christopher Weaver
Project Engineer
FLEXAN LLC / MEDRON LLC

About MEDRON LLC

MEDRON LLC, now part of FLEXAN LLC, is a recognized leader by global medical device OEMs for its strength in product development and design for manufacturability. They manufacture numerous life-saving medical device assemblies in addition to other outsourcing services including, high-volume manufacturing, customer private label capability, and thermoplastic extrusion services.

The Challenge

As a MedTech Molder, we utilize multiple high precision molded parts in our assembly automation cells to produce the final medical product that needs to be shipped to stock at the original equipment manufacturer. We needed to minimize the cost of scrap on a high dollar finished device—just one bad part out of a 12-component assembly can cost a lot of money. There is no rework.

In order to address this challenge, we tried standard methods of sticking to the process run sheet set points from run to run. We also implemented the use of the process monitoring features on the machine to identify possible variations. Though the results were good, we always seemed to be chasing something on the higher precision parts with tighter process windows. This was in part due to following traditional process developments instead of a systematic molding approach.

The Solution

In 2001, Doug Thorpe, then a Nypro Project Engineer, attended a local Executive Overview with Rod Groleau, founder of RJG. Thorpe quickly completed RJG Master Molder I and II as well train the trainer. I was a student in Thorpe’s first class at Nypro’s Learning Center in 2003 and became a certified trainer in 2007.

We were so enlightened and recharged by our experience in the course, we decided to continue training our workforce through RJG. All of our technical resources, as well as non-technical, are encouraged to attend some level of RJG training in order to develop a common understanding of the challenges we face as a MedTech (and packaging) injection molder / assembler.

After an initial 15-machine trial in 2004, we have since outfitted our entire fleet of machines with eDART® Systems. We have now been working with RJG for over 10 years, for both training and technology. In that time, we standardized on cavity pressure sensors where applicable and learned a ton as a team. It has been a learning curve to get to where we are today, but it has grown into part of our culture.

The Result

Nypro has since made the use of RJG methodologies a part of our everyday culture, from Systematic Process Development through production process control/monitoring/sort for the final molded part. We have standardized the use of systematic decoupled molding process development and implemented the use of cavity pressure technology part containment. RJG’s technology also allows us to measure and reduce cavity-to-cavity variation.

Utilizing RJG’s technology gave us the ability to see inside the process and understand what was going on. The eDART graphs allowed us to see the interaction of the press and cavity at the same time with respect to plastic pressure. Our customers now have an increased confidence in our capabilities, and we have become the least of their concerns in the supply chain.

Chris Lillyman
Manufacturing Engineering Manager
Nypro Healthcare, Clinton / Devens

About Jabil

Jabil is a product solutions company providing comprehensive electronics, design, production and product management services to global electronics and technology companies. Offering complete product supply chain management from facilities in 29 countries, Jabil provides comprehensive, focused solutions to customers in a broad range of industries.

The Challenge

The main problem for us is standardization—keeping a consistent process and a step-by-step guide to get the process back. The lack of both bring big repercussions to the quality of the final product. Customers require a lot of information on the quality evaluation, which can be difficult to gather and sometimes proper documentation doesn’t even exist.

The Solution

I heard of RJG from my boss four years ago and attended a Systematic Molding for Liquid Silicone Rubber course in 2015. It was eye opening to learn how to handle the process from the plastic’s point of view, and I learned that we can have standardized steps to get the process back. I continued onto Systematic Molding and obtained my Master Molder® I (MMI) certification in 2017.

The Result

Since my training, the process has improved both in silicone and plastic injection, and I have a better understanding of the process and improvements that can be made. The first indication of return on investment was the cycle time improvements, followed by the definition and standardization of the molding process and quality improvement.
Nowadays, our silicone process is the most stable at our facility. If a problem arises, I can get a process back in less than thirty minutes. One of my main takeaways from training is to document everything. Coming back from MMI, I parametrized every machine and mold using the process and tests I had learned. After testing four molds, I discovered that the process was set up incorrectly. These tests lead to developing an improvement initiative that will save our company half a million dollars annually.

The three consultants who have worked with me throughout my training path have provided me with the confidence to handle my own process. Their support when I reached out to them in each moment of doubt has been great. We plan to continue working with RJG in the future, including participating in their Master Molder® II program. RJG’s method of training made a huge impact on our company and will continue to make a difference in the industry as a whole.

Jose Bando Huerta
Mechanical Process and Molding Engineer
Robert Bosch Sistemas Automotrices SA de CV

About Bosch

Bosch is a global leader in the electronic industry. Our facility in Cd. Juarez Mexico is currently serving leaders in the automotive industry by providing high quality, high precision plastic and silicone injected parts. Bosch began operations in Mexico in 1955, importing for the local automotive, electrical, and diesel products—both aftermarket and original equipment. Since then, Bosch has been involved in industrial development and contributes to the growth of Mexico.

The Challenge

Before working with RJG, the majority of our processes did not utilize DECOUPLED MOLDING® strategies. We faced a lot of inconsistencies from part to part, so we had to find a way to standardize our processes and create consistency across all of our parts.

The Solution

I first heard about RJG back in 2004. Century Mold sent all of our set up/process technicians and some of our support departments to several RJG classes, including Systematic Molding, the Decoupled Workshop, and Math for Molders. I also completed Master Molder I in 2016. This allowed us all to be on the same page and gain a solid foundation on which to build.

The Result

Since then, we have established a process for troubleshooting and testing molds using RJG tools. We’ve been able to establish and maintain more robust processes and improve the overall consistency of our parts. Our processors now approach issues with the same mindset, and everyone who has participated in training has a clear understanding of the molding process. We reduced our scrap from 2% to 0.8% within 2 years and have saved over $173,000 in machine time. In addition, we were able to reduce customer complaints by 59% with RJG’s training.

RJG training is unlike any other injection molding training available today, and I believe the results we have seen speak for themselves. We’ve been able to eliminate ongoing quality issues that we weren’t able to resolve prior to working with RJG, and we plan on continuing to work with them in the future.

Ernest Freeman
Molding Supervisor
Century Mold

About Century Mold

Century Mold is a leading North American injection molder who services the automotive industry. Parts manufactured by the company can be found on all major OEMs such as Ford, GM, Chrysler, Toyota, and Nissan. Between these major car companies and many others. Century Mold has grown to seven locations within the USA and Mexico. With over 600,000 square feet and 150+ injection molding presses, the company continues to invest in the latest technology to keep up with customer needs.

The Challenge

We were faced with three main challenges: short shots, flash, and a lack of understanding the injection molding process. To combat this, four years ago we decided that we would invest in our molding capabilities. We purchased new injection molding machines, new auxiliary equipment, and robots and started investing in all new molds. This was great and helped get us back on track with better quality and output. But there was still something missing.

Our scrap rate was 1.25%. The problem we had was that these parts are a safety and regulatory item that would be carrying fuel on vehicles. We couldn’t accept even one defect that could potentially cause fuel leaks or a dangerous situation in the field. We interfaced a robot with the machine trend chart and did a study to determine if the machine tolerances for the process were sensitive enough to constantly reject a short shot, no matter how small it was. It couldn’t.

Big problem…

The Solution

I have been using RJG methods my entire career. In 1996, my employer at the time sent me to attend my first RJG course: Systematic Molding. Then in 2007, I attended a Master Molder course and received my certificate. Soon after, I started working with large medical devise suppliers to streamline the build and leave no unanswered questions on part integrity based on the established process parameters.

Management was convinced that if we implemented the eDART®, set up all of our molds with end of cavity sensors, and interfaced to the robot, we would effectively capture potential defects as well as force the employees to understand the process and make better processing decisions.

The Result

After 11 injection molding machines and more than 35 molds were equipped with pressure sensor controls, our scrap and efficiency was amazing. Our scrap went from 1.25% to .25%, and our daily output went from 99,000 connectors to 150,000. By establishing tolerances on the end of cavity, we’re able to sort out every defective part before it even reaches the operator.

RJG offers unprecedented technical support, and their hands-on training courses provide a huge amount of helpful information. The level of difficulty and variety of lessons really makes the information stick. RJG has insured that our customers receive a high quality, consistent product that was produced by very competent employees.

Jamey Cates
Senior Process Engineer
TI Automotive

About TI Automotive

TI Automotive develops and produces award-winning, industry-leading automotive fluid systems. For almost 100 years, TI Automotive has provided its technology to vehicles around the world. With more than 120 manufacturing locations in 29 countries, our strength lies in our ability to creatively meet the ever-changing needs of the global automotive industry.

The Challenge

Many of the parts engineered at ICU Medical require extremely specific and precise molding processes, however ours revealed subtle inconsistencies that often resulted in questionable or scrap parts. We decided we needed to improve, maintain, and troubleshoot our molding process in order to provide consistency among process techs and methods and easily spot when processes were drifting.

The Solution

After searching through various options for molding training and technology, we decided to reach out to RJG for help. Getting buy-in was simple, as many of our engineers and techs were already familiar with their work. We brought RJG in, studied their scientific methods, adopted their philosophy, and entered our engineers and techs into their training program in order to implement their technology.

The Result

Since looking at the molding process from the plastic’s point of view, we have significantly reduced our time spent troubleshooting. By turning a trial and error process into a step-by-step walkthrough, we’re able to immediately understand what went wrong and why. This controlled environment speeds up production time, reduces scrap, improves overall quality, and ultimately increases our profit margin.

RJG also helped us create consistency between the engineering and production teams. The built-in log and template make it exponentially easier for techs to hand their machines over at the end of the day. They’re able to know exactly when there was an anomaly, why it occurred, and how the tech resolved the issue. Having actual values for process parameters rather than set points allows us to easily see the process and whether or not it has moved, which is not a feature available when using settings.

Overall, RJG was an investment worth making, one we’d gladly do all over again, and we look forward to continue working with them in the future.

Rick Godfrey
Molding Manager
ICU Medical

About ICU Medical

ICU Medical connects patients and caregivers through safe, life-saving, life-enhancing medical devices. We provide clinicians around the world with innovative and cost-effective patient care solutions for unmet clinical needs. Because our products are relied on to improve patient outcomes by helping reduce bloodstream infections and protect healthcare workers from exposure, it is crucial that every single part we make is of the utmost quality and precision. A single imperfection could be detrimental. Our desire to redefine the limits of patient and healthcare worker safety starts with our molding process.