Canadian Plastics 2014 INJECTION MOLDING SURVEY. *survey results based on 51 responses

Transcription

1 Canadian Plastics 2014 INJECTION MOLDING SURVEY *survey results based on 51 responses

2 Survey Methodology The Injection Molding Benchmark Survey was sent in December 2014 to 456 people at injection molding shops on the circulation list of Canadian Plastics magazine, with one survey going to one respondent per facility. It was ed up to three times if we had the recipient s address and received 51 responses.

3 1. Which best describes the molding operations at your plant? Custom molding with some proprietary molding 27% Captive molding with some custom molding 15% Exclusively custom molding 19% Exclusively proprietary 23% Exclusively captive molding 17%

4 2. What markets do you serve? (Check all that apply) Other 16% Medical 28% Electronic 20% Packaging 28% Consumer goods 41% Construction 33% Automotive 43%

5 3. Which of the following service capabilities does your plant provide its customers? (Check all that apply) Assembly 75% Mold manufacturing (in-house) 42% Welding/bonding 35% Printing/decorating 52% JIT production 48% Design (CAD) 65% EDI or e-procurement 33%

6 4. What percentage of your plant s 2014 budgeted expenses was allocated to employee training? 0% 15% 1% 34% 2% 30% 3% 17% 4+% 4%

7 5. What percentage of your plant s 2014 budgeted expenses went to product research and development, either on-site or off? 0% 17% 1% 23% 2% 15% 3% 11% 4+ % 34%

8 6. In which of the following areas do you have formally implemented policies and programs? (Check all that apply) Preventative/predictive maintenance 72% Modified work for worker comp. cases 26% Recycling/waste management/environmental 54% Cost reduction 52% Training 72% Safety 83%

9 7. Is your plant certified to an ISO or QS9000 standard? In process 15% No 30% Yes 55%

10 8. What kinds of polymers does your facility currently process? (Check all that apply) Bio-based/biodegradable resins 15% Specialty resins 39% Engineering resins 70% Commodity resins 78%

11 9. What do you estimate will be the total amount of resin consumed at your plant in 2014 in lbs? Average 5,272, ,000,000 2,000,000 3,000,000 4,000,000 5,000,000 6,000,000

12 10. What percentage of the injection molding machines at your plant fall into the following tonnage ranges? tons 19% tons 31% tons 31% tons 71% tons 76% 99 tons or less 76%

13 11. What was your average machine utilization rate for the past year? Less than 39% 0% 40-49% 5% 50-59% 10% 60-69% 20% 70-79% 27% 80-90% 24% % 15%

14 12. What was your plant s average part reject rate for the past year? 0-1% 20% 1.1-2% 33% 2.1-3% 20% 3.1-4% 20% 4.1-5% 5% Over 5% 3%

15 13. Of the projects you quote on, what percentage turn into business? 0-10% 10% 11-20% 28% 21-50% 41% 50+% 21%

16 14. Compared to 2013, how was your business volume in 2014? Down more than 10% 3% Down 6-10% 8% Down 1-5% 5% The same 20% Up 1-5% 10% Up 6 to 10% 23% Up more than 10% 33%

17 15. Compared to 2014, what do you anticipate your business volume will be in 2015? Down more than 10% 3% Down 6-10% 0% Down 1-5% 3% The same 15% Up 1-5% 28% Up 6 to 10% 15% Up more than 10% 38%

18 16. What percentage of your product is shipped outside of Canada? 0-25% 35% 26-50% 20% 51-75% 20% Over 75% 25%

19 17. What is the number of injection molding machines at your plant? % % % %

20 18. What percentage of your machinery is more than five years old? 0-30% 13% 31-50% 18% 51-75% 18% Over 75% 53%

21 19. a) Were any new injection molding machines purchased for your plant in 2014? No 48% Yes 53%

22 19 b) If yes, were the purchased machines Both 9.5% Pre-owned 28.6% New 61.9%

23 20. Will new injection molding machines be purchased for your plant in 2015? Don t know 45% No 23% Yes 33%

24 21. a) Do you intend to buy Both 21% Pre-owned 29% New machines 50%

25 21. b) Is it for replacement of old equipment or for additional capacity? Additional capacity 66% Replacement 35%

26 22. Was any auxiliary equipment purchased for your plant in 2014? No 28% Yes 73%

27 23. Will new auxiliary equipment be purchased for your plant in 2015? Don't Know 38% No 3% Yes 60%

28 24. a) Were any new linear (3-axis) robots purchased for your plant in 2014? No 68% Yes 32%

29 24. b) Will any new linear robots be purchased for your plant in 2015? Don't Know 36% No 31% Yes 33%

30 25. a) Were any new articulated (6-axis) robots purchased for your plant in 2014? No 82% Yes 18%

31 25. b) Will any new articulated (6-axis) robots be purchased for your plant in 2015? Don't Know 36% No 49% Yes 15%

32 26. How many employees work at your plant? % % % % % %

33 27. What is the hourly rate paid to a machine operator, excluding benefits? AVERAGE $

34 28. Please select the province/territory where your plant is located: Alberta 3% British Columbia 11% Manitoba New Brunswick Newfoundland Nova Scotia NWT Nunavut 0% 0% 0% 3% 0% 0% Ontario 63% PEI 0% Quebec 18% Saskatchewan Yukon 0% 3%