McClarin Plastics specializes in providing plastics and fiberglass solutions for industrial and construction equipment, recreational and transportation components, along with renewable energy and medical applications.
When the composites industry began more than 55 years ago, McClarin Plastics was there. The company was founded in 1953 and has been under the current ownership since 1983. Today, they serve customers in 23 states and five countries from three manufacturing facilities in Hanover, Pennsylvania.
McClarin Plastics’ product solutions include Fiberglass Reinforced Plastic with Open Mold, Vacuum Infusion, Resin Transfer Molding (RTM) and Cold Molding. Our Thermoforming, operation forms ABS, polycarbonate, PETG, Styrene, TPO, PC/ABS and polyethylene.
A cohesive team of over 200 employees are dedicated to taking your project from concept to finished goods with aggressive value-added opportunities, and extreme attention to style and quality.
Company Overview
McClarin’s team approach includes:
Design Engineering Review using FMEA
Value Engineering Management
Project Engineer Assignment and Contract Review
Project Management with Tracking Reviews and Timeline Matrix
Continuous Improvement with KAIZEN and 5S
Continuous Improvement Employee Feedback Programs
Quality with ISO 9001:2000 Certification and Six Sigma
Company Profile
McClarin Plastics has a 55-year history of providing economical and progressive solutions to their customers through:
Engineering Flexibility. McClarin Engineers use SolidWorks and Pro-E to provide CAD, digitizing, computer aided manufacturing support and design solutions.
Innovative Manufacturing Process Design. Our dedication to continuous improvement and process flexibility integrates CNC 5–Axis trimming, workcell manufacturing, Lean methodology and Six Sigma protocol.
Quality Molds and Fixtures. We believe that quality molds and fixturing are the key to successful component manufacturing. Using conventional construction and CNC machining, McClarin Plastics can engineer and manufacture molds and fixturing to meet your design specifications.
Company Profile
Accomplishments
ISO 9001:2000
– Earned in 2006
100 Ton State Permit, both EPA and Pennsylvania DER
– Continuously maintained since 1986
Federal MACT (Maximum Achievable Control Technology)
Maintains emissions at just 8% of the allowable standard
Plastics News’ Top 15 Heavy Gauge Industrial Thermoformers in North America
Honored as Manufacturer of the Year by the Manufacturers’ Association of South Central Pennsylvania (MASCPA) in 2005.
Capabilities
Thermoforming and Fabrication (Sheet material .06 to .500 gauge)
Resin Transfer Molding
Vacuum Infusion Molding
Pressure Forming—Sheet material .060 to .187 gauge
Tooling engineering in-house with direct CNC mold machining capability
Faro Arm Digitizing and CMM
Company Profile
Dedication to Excellence
Global Standards for Plastics Certification
– 20 Thermoforming employees certified to date, goal to have all employees certified by 2010
Certified Composites Technicians
– 1 certified Composites Instructor
– 27 Certified Composites Technicians
l Lean Principle Culture
l Six Sigma processes
– 2 Black Belts on staff
– 1 Green Belt on staff
Just In Time (JIT) and Contract purchasing
Maintains an environmentally friendly facility
Employee Education – over 20 training and education programs in place, including:
– Manufacturing Economics Course (9) 2-hour in-house classes, all employees are scheduled to attend.
– Language of Manufacturing Course Includes measurement, calibration, shop-math, blueprint reading, testing, evaluation, inspection, and electrical safety procedures
– Tuition Assistance
ISO Certification
McClarin Plastics, Inc. is registered to the ISO 9001:2000 standard. This achievement documents McClarin’s commitment to establishing and maintaining acceptable levels of measurable quality in our products and services.
As part of the ISO process, McClarin has created a Quality Manual and operating procedures which provide comprehensive evidence to all customers, suppliers and employees of McClarin Plastics’ dedication to continuous improvement. In order to meet those goals, McClarin will pursue the following objectives:
Provide our customers with only the highest quality products and services.
Provide those products and services on time and in the most efficient way.
Provide our customers with the best total value for products and services.
Provide open communications with our customers in order to meet the customer’s needs.
Provide a system of Continuous Quality Improvement.
Provide a system of employee involvement, motivation and training
Value Added Solutions
Providing Value Added Solutions is a priority at McClarin Plastics. Our team works with you to evaluate and identify what additional or special services your project may require. Our goal is to make your job easier and our relationship more beneficial. To do this, we offer solutions in Design, Assembly, Outsourced Operations, Packaging and Shipping.
Design
McClarin Plastics keeps up-to-date with various software packages to support customer design requirements. Utilizing SolidWorks, Pro-Engineer and Surfcam, we offer assistance in design from concept through manufacturing with updates as required. Software versions are available to suit customer needs so that communication between McClarin and customers runs as smoothly as possible.
If a customer-supplied design needs updating but timing or personnel are not available, we will be happy to provide support. No job is too small or too big for the McClarin design team. Additionally, we have the capability to facilitate our customers’ desire to convert metal parts to plastics, saving weight, assembly time, and improving the aesthetics of their product.
Value Added Solutions
Assembly
With over 60% of our manufactured components requiring secondary assembly, we’ve developed an extensive list of suppliers from which to source any needs you may have. Our purchasing team is focused on managing your component sourcing and assembly using Lean principles while exceeding your expectations.
McClarin Plastics can develop a comprehensive Bill of Material (BOM) system to manage and organize all of your component parts. You’ll only have to issue one purchase order and we will take care of the rest.
Outsourced Operations
Finding and coordinating outside operations can be daunting. McClarin Plastics has located reliable, quality organizations to supply materials and services. Our sources provide painting and coating services, component manufacturing as well as packaging services. Painting and coating services include spray coat, powder coating, RFI shielding materials (copper), and heat shielding materials. We have sources that provide additional component manufacturing such as foam production, machining and electrical outfitting.
Value Added Solutions
Packaging
We know your component inside and out, so who better to help assist in determining your packaging requirements? We will help you choose the right solution to meet the specific needs of your project. Our team will assist in the design of crates and packaging for direct ship requirements including wood, foam and cardboard options as well as returnable packaging such as metal crates and totes.
Shipping
Based on your needs, our team will design and coordinate the best shipping scenario. The majority of our shipping profiles are FOB: Hanover, PA.
McClarin Plastics offers local delivery via our fleet of two tractor-trailers, a 24ft. box truck, van and three pick-up trucks. For longer haul shipments, we will work with you and your standard freight carriers or through our relationship with two local carriers who deliver based on set trips and rates.
McClarin Plastics is continually developing improvement focused programs and is always available to meet customer requested business and systems support programs.
Contract Manufacturing
Whether it is because of growth, a shift in strategy, or a concentration on core competencies, your company may need to consider outsourcing the manufacture of new or existing assemblies and products.
McClarin Plastics offers a full service Contract Manufacturing solution to meet your needs. When contracting with McClarin, we can create a manufacturing facility dedicated to the production of specific component assemblies or your entire product.
Contract Manufacturing offers a myriad of benefits:
Relief from equipment burden— procurement and maintenance
Eliminates the cost of new facility construction or expansion
Less overhead
No product tooling or design
Substantially reduced operation costs
Contract Manufacturing
When you decide to Contract with McClarin, our team will assess the project scope and manufacturing processes. We will then submit a preliminary design concept and budget which includes a plan for any capital investment and staffing. During this due diligence time, we will work with you to determine mutually agreeable project requirements, demand expectations, delivery needs and payment profile agreements.
Contract Manufacturing Profile
Contract Manufacturing constitutes 80% of McClarin Plastics’ sales. With a major focus on working with market leaders that use contract programs, we have developed an unparalleled skill set which includes Value-Added solutions.
Contract Manufacturing
Contract Manufacturing and the Lean Philosophy
Our philosophy is to produce only the necessary units, in the necessary quantities, at the necessary time and to eliminate unnecessary inventories.
While we do focus on all “7 Wastes” (waiting, transporting, processing, unnecessary stock, unnecessary motion, defective goods and over-production), our highest priority is the elimination of over-production. This is integral to achieving our goal as a Contract Manufacturer—your needs pull our production.
McClarin Plastics has been practicing the Lean methodology for the systematic elimination of waste since 2000. Lean manufacturing principles help ensure we are balancing your needs with the project costs.
Thermoforming Solutions
Thermoforming offers three main competitive advantages:
• Lower mold costs
• Shorter lead times
• Large part capacities
McClarin Plastics offers three thermoforming processes: Vacuum Forming, Pressure Forming, and Twin Sheet Forming. These processes can accommodate heavy gauge (.064–.500) materials; however, each process provides different benefits. Our team of engineers will work with you to determine which process best meets your needs.
Vacuum Forming
Cut-to-size sheets are heated in ovens by ceramic or gas heaters. Zone controls are used to maintain accurate temperature measurement and control. Once the sheet reaches the appropriate temperature, it is placed over a mold and a vacuum is applied to pull the sheet into the mold. This process is especially good for manufacturing large parts.
Vacuum Forming usually offers the lowest tooling costs and quickest delivery of tooling when compared to other production plastic molding processes.
Thermoforming Solutions
Pressure Forming
Pressure Forming uses the basic principles as Vacuum Forming, except that the heated plastic sheet is pushed into the mold using air pressure. For parts that require high styling and aesthetic detail, Pressure Forming is a good choice as it allows for textured surfaces, undercuts and sharp corners.
Twin Sheet Forming
This process is used to add structure to thermoformed components. In Twin Sheet Forming, two sheets of material are simultaneously moved between opposing molds, vacuum formed into their respective molds and then pressed together. The pressure on the two molds and squeezing the sheets together creates an excellent bond similar to a thermoweld.
Equipment
Employing Lean principles, each of McClarin Plastics’ thermoforming machines are coupled with its own CNC router. (See our Equipment list for details.)
Fiberglass: Vacuum Infusion
Vacuum Infusion is a cleaner process for both the environment and employees. There are no styrene emissions and a cleaner working environment is maintained. Because the process is very visual, action can be taken to correct any problems as the part is being molded, resulting in fewer reworks and scrapped parts. In traditional spray-up molding, a problem isn’t known until the part is demolded. The Vacuum Infusion process also produces a stronger part than the traditional process with up to 50% glass-to-resin ratio.
Fiberglass: Vacuum Infusion
Vacuum Infusion also provides a number of other improvements over traditional methods. These include:
Higher strength-to-weight ratio than hand lay-up or spray.
The process is clean, efficient, and capable of producing stronger and lighter parts than conventional methods.
Consistent wall thickness.
Resin usage becomes very predictable and manageable.
Lower weight, increased strength, maximization of the properties of fiber and resin.
Larger parts can easily be produced.
Vacuum Bag Molding uses a custom-made plastic bag and vacuum to draw the plastic and fiberglass into the mold. This molding technique makes it possible to obtain the highest fiber ratios and material strengths. Tooling and labor costs can be higher than Open Molding. Vacuum Bag Molding is good for large parts where surface and finish is not critical, such as wind power nacelles and infrastructure components .
Fiberglass Reinforced Plastics
Fiberglass Reinforced Plastics (FRP) are an ideal replacement to steel components. While noted for strength, lighter weight, corrosion resistance, and shorter lead times, the material can be used to create more contemporary looks because it can be molded into complex shapes. McClarin Plastics can process FRPs using various molding techniques: Open Molding, Cold Molding, Resin Transfer Molding, and Bag Molding using Certified Composite Technicians.
Open Molding
McClarin Plastics’ Open Molding process can be done using hand lay-up or spray lay-up. This process provides the quickest start-up with the most economical initial tooling investment. The Open Molding process is good for parts requiring high gloss surface finishes such as marine equipment, equipment shrouds and therapy equipment.
Fiberglass Reinforced Plastics
Cold Molding
Cold Molding combines low pressure with a room temperature curing system. The molds are made of metal, epoxy or polyesters. The technique allows for part tolerances to be more uniformly controlled. The technique also produces smooth surfaces on both sides of the part. The Cold Molding process is good for fan shrouds, ducts, partitions and upholstery substrates.
Resin Transfer Molding
Though the process is similar to Cold Molding, Resin Transfer Molding produces higher laminate strengths. These molds are more expensive than those for Cold Molds because they are more substantial to be able to withstand the injection of resins into the cavity. Resin Transfer Molding is good for parts with controlled features on both sides. Trays, shrouds, and body panels are examples.
Transportation
Planes, trains, rapid transit and commuter rail systems, buses, boats, cars and trucks. The demands on public and private transportation continue to grow as more cities find themselves faced with growing populations resulting in increased congestion and pollution. So the need for reliable, fuel efficient, user-friendly mass transportation is ever-increasing.
The Challenge
Few suppliers are qualified to answer the call for help because of the special production specifications required for the transportation industry. The ability to provide materials that meet stringent guidelines for flammability, durability, smoke emission and toxicity eliminate many suppliers from consideration. But McClarin Plastics has passed the tests and has the capabilities to supply parts to the transportation sector. Our on-staff internal design specialist has over 20 years experience in transportation interiors.
Transportation
Our Experience
Using Thermoforming and/or Fiberglass Reinforced Plastics technology, we are able to provide the design, engineering, tooling and manufacturing solutions you need for the creation of parts for transportation on land, by sea or in air. We also offer a variety of production options to accommodate international needs so part costs are minimized while customer service support is maximized.
Solutions
Automotive Ground Effects
Bus Interior/Exterior Components
Mass Rail Transit Interior Components
Automotive Interior Components
Seat Backs
Truck Interior/Exterior Components
Airline Seat Components
Facilities
McClarin Plastics, Inc.’s facilities are the finest in terms of innovation, repeatable quality and dependable service. All of our operations are located in Hanover, PA and we now have over 200,000 square feet of manufacturing space and a new corporate headquarters. We are geographically situated to serve North America and Europe with accessible transportation.
Thermoforming & Pressure Forming Facility
Our Thermoforming and Pressure Forming facilities operate from 120,000 square feet of space. We thermoform product components for the medical, construction equipment, transportation and recreational industries from clear Lexan as well as ABS, HMWPE, High-Impact Styrene and specially engineered thermoplastics. Our facility produces products such as machinery enclosures for JLG Industries and decorative boat interior components for Bombardier Recreational Products.
Facilities
Fiberglass Reinforced Plastic Facility
Our FRP manufacturing facility operates in a 65,000 square foot property. Examples of molded parts we produce by FRP include construction equipment covers, toilet modules for Amtrak, transit rail car interior systems for ALSTOM and RailPlan International, as well as industrial equipment enclosures.
Renewable Division Wind Energy Facility
To accommodate new production volumes, McClarin has built a new 60,000 square foot manufacturing facility that produces and assembles components for one of the top three wind energy developers in the world. Using the Vacuum Infusion method, which allows us to produce larger parts, we produce 5 nacelles and spinner nose hubs each week.
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