CONSULTING. for the Injection Molding Industry. Expert Advice Tailored to Your Needs

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1 CONSULTING for the Injection Molding Industry Expert Advice Tailored to Your Needs

2 Why RJG Consulting? Learn from Industry Experts Our consultants are a hot commodity. Why? Because they ve been in your shoes. They re injection molders, designers, engineers, and plant managers. They know the ropes and are masters of finding solutions to complicated problems. The best part? They can t wait to share that experience and knowledge with you. Our Outstanding Reputation Results of RJG Consulting Services: Improved cycle time Improved machine utilization Reduced scrap Improved quality Reduced time to market (faster startups, reduced cycle times, decreased downtime) Ability to uncover and fix problems Decreased tool damage No more mold re-cuts Faster tool launches Optimized design Consulting Services Available Gap Assessments: A consultant will spend two and a half days at your facility performing an in-depth assessment of everything from design to production. Problem-Specific Consulting: Whatever your struggle or opportunity, we can work with you to develop the right solution for your business. Post-Training Application: We will work with your staff to help them apply what they learned in the classroom to the plant floor. TZERO Consulting: RJG s TZERO program helps world-class companies cut the cost and time wasted on adjustments during a tool launch. We ll Come to You You don t need to stress about paying for travel costs or making complicated plans we will send our experts to you. By working at your plant, we re able to deeply understand what your molding, how you re molding it, and what problems you may be facing during the process. We will dig our heels in and work with you until the perfect solution is found. Working with RJG s TZERO group has proved to have a huge value in the development of our product. With RJG s TZERO group we were able to identify inadequate part designs, predict molding defects, optimize mold design, and pinpoint potential assembly complications through numerous simulations. In the end, the work with TZERO provided significant improvements in all areas that will save the company an estimated $4 million per year in piece price. Access Business Group, LLC. 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. Rick Godfrey, ICU Medical RJG was able to help us from concept and design to our plating process. They truly understood our needs from the plastic s point of view and helped us better integrate our plating process. We re now able to perform proper analysis with our specialized process considerations. Design, quality, process, and tool launch improvements saved us time, money, and scrap. Sean Whittum, Tribar Manufacturing 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... 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, Nypro Healthcare

3 RJG Gap Assessment Custom Consulting Systematic Molding Gap Assessments Consulting Built Around You As part of our consulting program, we offer a two-and-a-half-day Systematic Molding Gap Assessment of your company that audits your internal processes. Once the assessment has been completed, we make recommendations for improvement to your internal processes, assist your team with a plan for improvement, and mentor you through the implementation phases. No matter if you re struggling to get a tool to run, looking to improve your process times, or anything in between, we will work one-on-one with you to solve any of your molding problems. Our consultants are experts at what they do and will jump through whatever hoops necessary to get your processes running perfectly and your customers happy. Our goal is to make you look good. Simple as that. What We Will Assess Get Your Team on the Same Page We will review a variety of aspects of your business, including: machines, materials, personnel, training initiatives, organizational charts, company goals and objectives, reporting methods, plant layout, shut down procedures, processes, internal procedures, and more. We ll complete a checklist prior to visiting to ensure we have a good understanding of your business before we even enter the doors. We find that more often than not, there is some kind of disconnect at some point in the process from design to production. Our consultants can ensure that every team member is on the same page and resolve any kinks or misunderstandings along the way. The GAP Assessment Process: Our consultants work alongside your regional manager, account coordinator, and customer support person to get a full picture of your unique situation. They won t show up to your facility blind, they ll have an understanding of your background and interactions with RJG up to that point and use that knowledge to build a custom coaching program just for you Determine if the GAP Assessment is right for you Complete a pre-audit checklist before visiting In-plant walk around Hold a kick-off meeting Interview employees Complete the audit investigation Calculate Gap Assessment score Present findings Make recommendations Next steps The Final Deliverable Once the assessment is complete, our consultants will create an in-depth PowerPoint presentation of their findings. We will explain exactly what we found, what s working, what isn t working, and present a suggested road map for the future. This will include several recommendations for how to address problem areas and resolve them as well as mechanisms for maintaining and updating change. Specialized Team-Based Directive Post-Training Coaching Learning in a classroom has its advantages, but sometimes it can be difficult to take those concepts and apply them to the real world. We can help bridge that gap by coaching students on their plant floor once class is complete. Our consultants will work with management to create Hoshin projects for students. This encourages both management and staff to get involved and solidifies complex concepts. In-Plant Audits If you re looking for a lighter version of our GAP Assessment, we offer problem-specific audits. Whether you want to know if your process is running to template, if you re processing at an appropriate level, or if you have any other specific concern, we re here to help. We can pinpoint the exact cause of your problem and provide detailed recommendations for moving forward. Schedule Around Your Timeline Midnight shift change? No problem! Just need a couple hours? We got you. Looking for a long-term relationship? We re here for you. Whenever, however long you need us, we ll be there.

4 TZERO Consulting TZERO Consulting Faster, Smarter Product and Part Launches Part Design Analysis RJG s TZERO engineering service helps world-class companies reduce the cost and time wasted on adjustments late in product launch. Our unique TZERO approach provides a framework for collaboration between engineering and manufacturing from concept to saleable product. We begin with the end in mind, meaning we need to understand the part performance criteria and work backwards through each step to ensure at every stage of the product, the plastic s point of view is considered. Part Design Analysis provides design and product engineers with a valuable tool to effectively analyze their part or product. We provide evaluations of the part geometry from the processing and tooling standpoint to determine if the geometry design is injection moldable. We must also consider the material that has been selected and assess if it s moldable in the geometry that has been designed and applicable for the end use environment. Further review is required in the performance criteria arena such as, but not limited to, datums, dimensions, tolerances, and colors to confirm design intent is achievable. How Did TZERO Get Its Name? T0 is the first time a mold sees plastic after it is designed and manufactured. In our industry, rarely does the mold or part meet all of its requirements at T0. On a regular basis, gates must be enlarged, vents added, or steel groomed. Unfortunately, this leads to T1, or the second trial for the mold. Often, there are days or weeks between T0 and T1 depending on the complexity and quantity of changes needed. We have seen molds reach T10 or higher before they get through the validation protocol. The goal of the TZERO initiative is to ensure that good parts are made from the first shot so that molds never have to enter into T1. Why TZERO? Well, it s because hope isn t the most effective strategy known to man. Making changes after the steel has been cut, or even worse the mold is in production, can be staggering. Without a scientific approach, it s highly likely that time-consuming and costly engineering changes will plague the project, pushing it over budget and behind schedule. Our skills, knowledge, experience, and tools allow our group to systematically identify problematic areas early on in the project. Working within the requirements of the OEM, the mold design, and the equipment at the molder is imperative to achieve success. Mold Design Analysis Mold Design Analysis provides OEM, mold designers, and molders with an invaluable mechanism to evaluate an injection mold. It is critical to ensure the mold has structural integrity so that it may endure the abuse that it will receive during its life of service. Equally important is to ensure that the mold has been designed from the plastic s point of view, from the melt delivery system to venting, cooling, and ejection. We must combine the previous areas with commercial requirements, like cycle time and cavitation, and couple that with the equipment capability at the molder. Injection Molding Simulation RJG offers simulation services from Moldex3D, Sigmasoft, and Autodesk Moldflow Insight. Through injection molding simulation analysis, our team can evaluate all aspects to identify potential molding defects that can lead to high scrap rates, poor quality of molded or assembled products, and excessive cycle time. Not only do we take into account the requirements of the OEM and mold design, but we also consider the machine capability at the molder.

5 Locations USA RJG USA (Headquarters) Traverse City, MI phone: SE Regional Training Center Woodstock, GA phone North Carolina Training Center Gibsonville, NC web: Mexico RJG Mexico Chihuahua, Mexico phone: web: es.rjginc.com France RJG France Arinthod, France phone: web: fr.rjginc.com Germany RJG Germany Karlstein, Germany phone: +49 (0) web: de.rjginc.com UK/Ireland RJG Technologies Ltd Peterborough, England phone: +44 (0) web: Italy Next Innovation Srl Milano, Italy phone: web: it.rjginc.com Singapore RJG (S.E.A.) PTE LTD Singapore, Republic of Singapore phone: web: en.rjginc.com China RJG China Chengdu, China phone: web: zh.rjginc.com Korea Caepro Seoul, Korea phone: web: RJG Headquarters