Archive for Lean Manufacturing

5 Questions to discover if your manufacturer can produce high quality parts, time and time again?

5 Questions to discover if you manufacturer can produce high quality parts time and time again?

The heavy gauge plastic thermoforming process can produce a very versatile range of highly detailed, durable, and tight tolerance parts with almost limitless design possibilities. The process is fast, cost effective, and ideally suited for a large list of markets and applications. However, like all manufacturing processes, plastic thermoforming requires technical expertise, detailed operating procedures, engineered tooling design and construction, and a comprehensive quality management system to ensure the consistent production of the most cost-effective solutions at the desired level of quality.

As such, not every plastic thermoforming processor is equally capable. Contract manufacturers with poor tooling, processing and quality controls can end up delaying your project or OEM product and increase costs.  Productive Plastics recommends asking the following questions to gauge if a custom plastic manufacturer will be able to consistently produce parts at your required level of quality and dimension tolerances.

1. Does the manufacturer have an accredited quality control program?

ISO 9001:2008 certification provider's logoEnsuring that your manufacturer has adopted an accredited quality control program, such as ISO 9001, will indicate that the company has an active quality control process in place that has been evaluated and certified by an industry recognized third party. The accreditation documentation, often available on the manufacturer’s website, will give you detailed information on what aspects of the company have been certified and supporting quality documentation can often be requested from the processor.

2. Is the manufacturer’s facility organized and clean?

This may seem like a trivial point, but it can be a key indicator Plastics manufacturer, plastics manufacturing facilityto a company’s commitment to quality. A company with a well-organized manufacturing floor is much more likely to take quality, efficiency, process improvement, and safety seriously. If you are not offered a tour of the facility, ask for ne and witness firsthand the quality control measures in action. Cleanliness and organization are vital since thermoforming is an “open mold process” meaning airborne dirt could end up as an inclusion in the finished part and become a cosmetic flaw.

3. Does the contract manufacturer utilize efficient manufacturing methodologies and conduct process improvement events, such as Lean Manufacturing and Kaizen events?

Lean Manufacturing practices are focused on the removal of inefficient practices in manufacturing, management, and administration operations and part of the methodology is the regular evaluation of current processes with emphasis on continual improvement. Companies that are committed to following Lean Manufacturing techniques often have a very efficient manufacturing operation, state of the art equipment, and produce quality parts with a low rejection rate.

Plastic thermoforming temperature controlled aluminum tool

4. Does the thermoforming processor have dedicated engineering experts on staff (in-house) to provide tooling design and construction project management?

Properly designed and constructed tooling is the foundation of plastic thermoforming and is essential to producing a high quality consistent product. Poorly engineered tooling can result in part dimension variations, surface abnormalities, and other defects. See 6 Common Thermoforming Quality Issues Actually Caused by Improper Tooling.

5. Does the processor conduct a “Define and Discover” Innovation Engineering approach to seek avenues for collaborative project development and management?

This collaboration innovation technique sets the stage for a smooth product development which is more likely to meet performance and delivery expectations.

Ultimately, each project is unique. A commodity type part will likely not require the same level of quality in detail and precision as a multi-part medical device assembly. However, finding a reliable custom manufacturer that can produce your parts consistently, efficiently, and to your specification is a paramount factor to the success of any product.

 

At Productive Plastics, we go to great lengths to ensure quality

Have more questions about the role of quality manufacturing for your parts and components? Interested in exploring plastic thermoforming solutions for your OEM product?

Please contact us.

Please contact Productive Plastics for more information on the thermoforming process

Lean Principles in Plastic Thermoforming Design

Most people familiar with the manufacturing industry associate the words “Lean” and “Process Improvement” with operations directly on the manufacturing floor. However, a manufacturer that strives to be a Lean Enterprise incorporates the practice of perpetual improvement and reducing waste (resources or time spent on non-value added functions) to every facet of their business.

One of the processes that is both critical to a project’s success and an ideal candidate for lean practices is the design engineering process. This is where customer designs are matched and adapted to the appropriate thermoforming technique, material selections are made, and proper tooling is assessed or engineered, setting the stage for a successful part run. This is a process with many variables that can have a large impact on quality, lead time, and cost.

Lean Principles in Thermoforming Design at Productive Plastics

What are the benefits of working with a manufacturer that utilizes Lean practices in the design process?

  • Working with a manufacturer that has standard operating procedures and practices documented and employed to take your project from design to production as quick as possible while avoiding common pitfalls and any non-value added endeavors
  • Design assistance for a seamless transition from the client’s required design specifications to a thermoforming process ready design
  • Savings in cost and time
  • Increased part quality and lower part defect rate

How does Productive Plastics apply lean principles to the design process?

As an example of how lean principles and process improvements can be applied to design practices in the thermoforming process, reference the chart below for functions we have identified as actual or potential waste, the actions we have implemented to eliminate or mitigate waste, and the results.

Identified Waste

Process ImprovementResult
Waiting

• Late tooling and assembly component quotes and delivery from suppliers

• Incomplete/inaccurate data

• Concurrent Engineering

• Gantt Chart Development

• Standard Operating Procedures & Guidelines

• Reduced lead time

• Reduction in resource utilization

Unnecessary/Incorrect Processing

• Incorrect material or process selection

• Incorrect manufacturing technique

• Early involvement and collaboration with client in part design

• Value Engineering Review

• Reduced lead time

• Maximize part consolidation and weight reduction

• Reduced defect rate

• Potential cost savings

Unnecessary Movement

• Development and design process requires revision due to inaccurate information

• Standardized Contract and Scope Review

• Standardized Design Review and collaboration with client engineering

• Define & discover collaboration

• Reduced lead time

• Reduction in resource utilization

Defects• Standardized Design Review and collaboration with client engineering

• ISO Certification

• Reduced lead time

• Reduced defect rate

• Potential cost savings

Unused Team Resources

• Losing time, ideas, skills, and improvements by not engaging employees

• Investment in people and company culture

• Company core values

• Collaborative planning, goals, and accountability

• Maximize employee engagement

• Reduced lead time

• Expertise and professional development within employee group

Productive Plastics is top contract manufacturer for heavy gauge thermoforming, including vacuum forming and pressure forming. Contact us or request our complimentary thermoforming design guide for more information.

Please contact Productive Plastics for more information on the thermoforming process
Please download our complimentary thermoforming design guide for more information on the thermoforming process

Lean Culture, Process Control, & Improvement

You may have heard the saying “If you always do what you’ve always done, then you’ll always get what you’ve always got.” Well, at Productive Plastics, we take this saying literally, and since we are always striving for innovation, efficiency, and a superior quality thermoforming, we are constantly evolving our business practices and processes to achieve these goals. Since 1998, Productive Plastics has adopted a lean culture approach to our business both on and off the manufacturing floor and, in recent years, we have integrated TPS (Toyota Production System) as the means to implement lean tools and practices.

Process control and improvement - lean manufacturing at Productive Plastics

What is lean?

“The core idea is to maximize customer value while minimizing waste. Simply, lean means creating more value for customers with fewer resources.

A lean organization understands customer value and focuses its key processes to continuously increase it. The ultimate goal is to provide perfect value to the customer through a perfect value creation process that has zero waste.” Lean Enterprise Institute

So what does this mean for your project?

From experience, we have learned that the benefits of this approach are, in fact, tangible for both the customer and the manufacturer. Substantial reduction of lead time, associated costs, and attaining a consistently high part quality are just a few of the advantages resulting from a truly lean approach to manufacturing and business.

Look for further content in the near future exploring in greater detail some of the features and benefits of working with a manufacturer that utilizes lean techniques in the design and manufacturing process. You can also visit our manufacturing page for more information.

 Regards,

Evan Gilham - Productive Plastics COO