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

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.