Overview The PRISM Way Facilities Technology Process Success Stories Wrap-up
The PRISM Way Works! Our Philosophy Lowest overall cost model = highest level of customer satisfaction Investment in, and full utilization of, technology Tight tolerance, precision components Environmentally responsible Organizationally flat and lean Financially stable
Facilities Chesterfield, MI - Port Huron, MI - Harlingen, TX Equipment and processes are uniform and interchangeable Small, tightly controlled manufacturing environments Highly automated Climate controlled
Facilities Customer focused Modular, Reproducible and geographically flexible Centralized administrative support to maximize manufacturing focus Clean, bright, safe
Machinery and Equipment invest in application-specific technology 35 All Electric Toshiba injection molding machines (65T 390T) High pressure injection units maximum velocity for optimum fill Small barrel size reduced residency time for engineered resins State-of-the-art machine controls Yushin five-axis robots Quick change, part specific end-of-arm tooling Low RPM screenless grinders
Closed Loop Manufacturing Cells Automated machine side material handling Process consistency Reject containment on nine process variables Process monitoring Robotic start-up containment Tool preservation / tool damage protection
Tool Engineering Advanced Logic Shrink Analysis Beaumont Technologies Melt Flipper Runner Optimization Mold Build Standards CT Scanning Technology
Shrink Analysis
Beaumont Technologies Increased cavitation Shear / balance Melt flipper
Runner Optimization Minimization = Reduced Scrap Elimination = Hot valve gate Reduction = Process Variation
Mold Build Standards Geared towards precision product Highly inserted cavities and cores Results in quicker time to market Minimizes downtime Detailed product specific lessons learned section
CT Scanning Part to Part Comparison Part to CAD Comparison Void Inclusion Analysis Wall Thickness Analysis GeoMagic
Integrated Information Technology ERP / IQMS Quoting/Forecasting B.O.M. Inventory control Production scheduling RealTime production monitoring Shipping / Receiving Accounting Quality Project Management Preventative Maintenance Paperless Systems / Visibility / Accuracy / Immediacy
Environmentally Responsible Closed loop chillers High efficiency lab quality lighting Enclosed climate stabilized manufacturing Variable speed air compressors Falcon high efficiency thermal barrels Hot runner molding
Philosophy: Controlled Processes = Process Control All Disciplines From initial quote through accounts receivable, and everything in between Best Practices Implemented All processes All facilities Elimination of Waste and Variation
Results World class PPM metrics Supplier Quality Awards T1 Steering Supplier (2014) Perfect Quality Award Perfect Launch Award Customer Service Award Takata - Supplier of the Year Award (2013) Autoliv - Supplier of the Year Award (2011) Industry Awards/Recognition Plastics News Excellence Award in Customer Service (2014) Plastics News Processor of the Year Finalist (2014) INC 5000 List of fastest growing companies (2014)
Success Stories Lowest Overall Cost Model = Highest Level of Customer Satisfaction
Runner Reduction High pressure injection units Double cavitation From 8 to 16 cavities, Beaumont Technologies Cost save $325,000 on $0.036 part
Flow Analysis Grey box success Customer molded connector body Customer built mold Dead headed injection high shear Moved gate 0.040 Problem solved retained molding business
Multiple Critical Improvements Successful Material Change Doubled Cavitation Runner Optimization Gate Change Approx. Cost Save ($150,000) Poke Yoke