About Plastic Components

  • July 7, 2008

    • Tooling Press Release


    PDF Version


    The TPR contacted Plastic Components, Inc. in Germantown, WI, to learn about how this injection molding company has wowed the plastics industry with its business and marketing prowess and fully automated production facility. The company was honored this year by Plastics News as one of the top three Plastics Processors of the Year.

    What is your company niche, and what does your company do that is notable, unique or different?

    The distinctive characteristic of the PCI manufacturing strategy is the commitment to process automation and quality control. There are no operators involved in the manufacturing process. The entire facility runs on a fully automated basis; each production cell is a self-contained work-cell with the molding press as the cornerstone of an entire array of support equipment.

    Monitoring and measuring devices at Plastic Components, Inc. are used in a manner, which ensures that the measurement repeatability and reproducibility is known and is consistent. The entire facility is monitored by the IQMS Enterprise Resource Planning System; a software system used throughout the organization that provides immediate real-time feedback on every aspect of the production process for every production cell. Identification of the measurements to be made, the accuracy required, and selection of the appropriate monitoring and measuring devices is a quality methodology that Plastic Components, Inc. stands by to afford accuracy and precision in our custom injection molded parts. Unique to Plastic Components, Inc. is the Process Quality Plan shown below which clearly illustrates the specifications with photos as well as maintaining a quality log initialed by quality inspectors. The Marketing Strategies developed by Plastic Components, Inc. over the past 3 years have produced tremendous results. The marketing plan is divided into 3 separate phases:

    1. Market Research: The identification of target markets, and customers within those markets, who are likely candidates to benefit from the manufacturing strategy in place at Plastic Components, Inc.;
    2. Market Communications; The development of strategies to communicate with those prospects identified in Phase I; using Web-site, direct mail, electronic mail, letters from the President, electronic PowerPoint presentations, WebEx conferences and public relations (publications) tactics;
    3. Finally, professional sales presentations and personal visits.

    The benefits of this effort are readily apparent in the sales results for 2007; with 14 new customers and 53 new tooling programs awarded by customers with whom PCI had no relationship with as of mid-2006.

    When and how did you get into the industry, what attracted you to it?

    Tom Duffey, President and Owner, was a manufacturers’ representative in the early 80s. He represented a number of companies, two of which were in the plastics industry. Even in the 1980s, trends could be seen developing in the world of manufacturing. Some of the manufacturing industries, like foundry, were very mature and there wasn’t a lot of growth potential. Duffey felt the plastics industry had the most upside potential.

    The potential was transformed into solid success when Plastic Components, Inc. was formed in April of 1989 in Germantown, WI. As a new player in the plastics industry, Plastic Components needed an immediate ‘in’ with the purchasing crowd. Luring customers away from established producers would be difficult. Duffey’s idea would produce the needed parts in a unique and accurate way, while at the same time reducing the costs to manufacture the molded piece. He knew the business model had to compete in a global marketplace. Plastic Components, Inc. had to do something different right from the beginning. That ‘something different’ was complete process automation. Since Plastic Components molded its first part, the plant has been fully automated. We’ve never had an operator in the direct molding process… ever.

    Relate a notable "best time" for your company.

    The challenge, as with any company, is choosing a methodology to communicate the success of the business to its customers and prospects. The traditional method of communication is often a phone call or visit by the regional sales person. Using this method, the information can be passed on only if the sales person is successful in obtaining a visit, and has the ability to convey a large number of facts in the short amount of time allotted for his/her visit. Then, after ‘selling’ the company’s successes, the sales person then must find time to sell the company’s product. Since the sales person’s commission is typically based on product sales, and the time allotted on a CEO’s schedule for sales calls is shrinking, it’s not hard to guess which part of the conversation may be omitted.

    To accomplish this goal, Plastic Components implemented a fresh, multi-functional approach. The first step was to introduce marketing strategies to create new market opportunities and find customers in non-traditional ways. We needed to use that medium more effectively and not just as a static brochure.

    Similarly, relate notable challenges that your company has overcome.

    The U.S. injection molding industry has been decimated by off-shore competition over the last several years. Plastic Components, Inc. has survived and prospered as a result of unique manufacturing and marketing strategies that have positioned PCI as a true globally competitive supplier of critical plastic components to our North American customer base. Plastic Components Inc. has met the cost challenges of the global marketplace while maintaining a level of profitability sufficient to allow for our aggressive expansion. In addition, we continue to reinvest in the finest process and support equipment available in order to maintain our position as a low-cost producer in the industry.

    When you are working on projects with your customers, what aspects would you like them to better recognize?

    Some companies talk about customer service. Plastic Components, Inc. has taken steps to move beyond the words, connecting with its customers in a way that is rewarding for both the company and the people it serves. The talent and commitment Plastic Components, Inc. offers is in place to strengthen its partnership with customers, which is critical to its success.

    List newly acquired technology, machinery or key personnel (in last year).

    Plastic Components recently invested in four new electric injection presses, bringing the production floor to 42 machines in February 2008.

    New Toyos: 35 ton, Si55 ton, & Si150 ton

    New Nissei: 90 ton

    Due to the recent growth in business, the new presses represent the commitment to continuous reinvestment in technology ensuring greater energy and cycle time savings.

    Two SmartScope Flash 302 - Multisensor Measurement Systems have been added to the quality lab! This system allows the auditing team to obtain difficult measurements, capability studies and repeat with accurate evaluation of parts. The fully automated system has the ability to switch between vision, touch probe, and laser on the fly.

    Has your company recently expanded? Plans to expand or form partnerships/alliances?

    If Plastic Components, Inc. continues on the current growth path, critical decisions will need to be made by the end of the year as to whether another facility will be a part of the company’s future. We are currently land-locked and therefore no future additions can be added to the existing building.

    Are you involved in any industry organizations or educational programs related to the trade?

    Plastic Components, Inc. has been a member of the MAPP organization (Mid-America Plastics Partners, Inc. – www.mappinc.com). President/Owner, Tom Duffey has assumed a more devoted approach to the association serving as a Board Member last year and President this year. Tom’s active participation has connected him with peer groups that have served as an effective learning resource with other injection molders. In return, Tom’s contributions have afforded him the prestige of being an industry steward in the world of injection molding. Tom has been a speaker at MAPP’s Benchmarking Conference sharing with others our company’s success stories. Most recently, Tom was a presenter at the Plastics News Survival Boot Camp discussing not only techniques to survive in this volatile industry, but thriving strategies that have proven to position Plastic Components, Inc. as a strategic differentiator in the plastics industry.

    What do you think about changes occurring in the industry due to globalization? How has it affected the way you do business?

    In recognition of global competition, Plastic Components, Inc. sought out relationships with offshore tool makers for the production of customer’s tools. This resulted in significant savings to our customers versus the purchase of domestically produced tools. What places Plastic Components, Inc. at an advantage is the purchase of a domestic tool maker with whom they had a business relationship for many years. PCI has its own 2,000 sq. ft. in-house tool room which manages and maintains the quality of our customer’s tools. Once a tool is received from China, the in-house tool room will make any necessary modifications to support the proper production of parts. Premium tooling is purchased for customers at the most appropriate price. The implementation of the APQP - Advanced Product Quality Planning has benefited the entire organization since the management team of Plastic Components, Inc. spent several weeks in the training to address features for developing the manufacturing systems in determining
    customer needs, requirements and expectations. An eight page “New Project Launch Checklist”
    was devised to properly maintain and account for new programs. This cohesive advancement
    has proven to be an effective tool for our internal departments to assure a smooth launch for our customers.

    The commitment to this strategy requires capital expenditures across a broad array of technology that is well above the norm in the plastics industry. This investment must be aligned with a committed and talented workforce for successful implementation.

    The whole company is strategically organized to wring out all waste in the manufacturing process of plastic components. Not just material waste, but material availability, cycle times, machine set-up, maintenance, quality monitoring and mold layouts.

    What will the industry look like in 3 to 5 years?

    Obviously it’s difficult to predict the future as no one holds the crystal ball; but Plastic Components, Inc. is very fortunate to be positioned the way it is in this industry and that clearly is the result of an effective business model that includes our off-shore tooling strategy, effective marketing/branding strategies, efficient engineering talent, high automation on the plant floor – all supported by a working culture that includes a full respect for everyone’s thoughtful contribution to the success of the organization.

    Originally published in the Tooling Press Release.

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