Mack -- Plastic Molding, Metal & Manufacturing

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Learn more about Mack Molding, a 90+ year-old company that supplies custom plastic injection molding and contract manufacturing services to a variety of industries. 10 locations. ISO 13485. ISO 9001.

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Mack -- Plastic Molding, Metal & Manufacturing

  1. 1. Corporate Overview - Mack Confidential & Proprietary-
  2. 2. WHO WE ARE  Full-service contract manufacturer  Specializing in…  Custom injection molding  Painting  Metal fabrication  Machining  Assembly  Offering product development resources…  Product design  Prototyping  Engineering services
  3. 3. WHO WE ARE  Founded in 1920 – privately owned & operated  Headquartered in Arlington, Vermont  Three operating divisions, 10 locations  ~1800 employees  Annual sales: $260 million  No long-term debt, 5A1 D&B rating  Certifications  ISO 9001  ISO 13485 (Mack North, Mack Prototype, Mack Technologies)  ISO 14001 (Mack South)  AS9100 (Mack Technologies)  ISO/TS 16949 (Mack South)  FDA Registered (Mack North)
  4. 4. Mack Molding - North  Mack Molding/MackMedical  Product Development  Plastic Molding  Metal Fabrication  Paint and Assembly  Contract Manufacturing  Mack Prototype Mack Molding - South  Plastic Molding  Class A paint  Assembly Mack Technologies  Electronics Contract Manufacturing  SMT, Turn-key System Integration, PCB/System Level Test Development MACK Group SLA Rapid Prototyping  Fused Deposition Modeling  CNC Machining  LIM Cast Urethane  Low-volume Injection Molding & Manufacturing CORPORATE STRUCTURE
  5. 5. Mack Technologies Westford, Massachusetts Melbourne, Florida Juarez, Mexico Mack North Arlington, Vermont (2) Cavendish, Vermont Pownal, Vermont Mack South Statesville, North Carolina Inman, South Carolina Mack Prototype Gardner, Massachusetts LOCATIONS
  6. 6. WHAT WE DO  Contract manufacturing  Product design & development  Rapid prototyping & low volume manufacturing  Custom injection molding  Cleanroom molding  Finishing & assembly  Sheet metal fabrication  Full-service machining  Medical Class II/Class III contract manufacturing
  7. 7. DESIGN & DEVELOPMENT  Application Development Center  Engineering analysis  Supply base selection and management  Material and process selection  Tool design and management
  8. 8. DESIGN & DEVELOPMENT  Interactive feedback with designers  Mechanical design  Design for manufacturing  Moldflow  Finite element analysis  Process selection
  9. 9. MECHANICAL DESIGN
  10. 10. METAL-TO-PLASTIC CONVERSION Orthopedic Ankle Clamp
  11. 11. INDUSTRIAL & MECHANICAL DESIGN
  12. 12. PART MOLDFLOW
  13. 13. FINITE ELEMENT ANALYSIS
  14. 14. PROTOTYPING/LOW VOLUME MFG  SLA rapid prototyping  Fused deposition modeling (FDM)  CNC machining  LIM cast urethane  Low-volume injection molding (10-230 ton)  Extensive finishing capabilities
  15. 15. CUSTOM INJECTION MOLDING  92 years of expertise  Six facilities  Vermont (3)  Massachusetts  North Carolina  South Carolina  120 injection molding machines  28-4000 tons  .6-800 ozs
  16. 16. MOLDING PROCESSES  Injection  Structural foam  Gas counter pressure  Gas-assist (internal & external)  Two-shot molding  In-mold decorating  Overmolding  Insert molding  High temp molding
  17. 17. INJECTION MOLDING  Molten plastic injected into a mold under high pressure  Fast cycles  3-5 ton/sq in clamp required  Lowest part weight  Good surface finish  Low molded-in stress
  18. 18. STRUCTURAL FOAM MOLDING  Molten plastic injected with a chemical blowing agent  Short shot process  Thicker part wall required  Low stress  Slow cycles  ¼ - 1 ton/sq in clamp required  Reduces sink issues  Rib-to-wall ratio can be greater  Poor surface finish; lots of swirl  Heavier part weight
  19. 19. GAS COUNTERPRESSURE  Structural foam shot into a pressurized cavity  Improved surface finish over structural foam  Cavity pressure holds out- gassing in check  Slightly heavier part than structural foam  Slightly slower cycle  Higher tool cost & maintenance
  20. 20. INTERNAL GAS-ASSIST  Gas confined within the part  Reduces sink  Reduces stress  Reduces press tonnage required  Longer flow lengths can eliminate need for manifolds  Licensed for any application
  21. 21. EXTERNAL GAS-ASSIST  Gas is pressurized between the core steel and the part  Reduces sink  Reduces stress  Must be confined by using core side part design
  22. 22. TWO-SHOT MOLDING
  23. 23. OVERMOLDING
  24. 24. LARGE PART MOLDING
  25. 25. RESIN PORTFOLIO
  26. 26. FINISHING & ASSEMBLY Automated Cleanroom Heat staking Testing Ultrasonic Laser welding Inserting Work cell RFID tagging Assembly Decorating Heat sealing Heat transferring Hot stamping Laser marking Pad printing Silk screening Painting Decorative Conductive Robots Automated Overhead lines Walk-in booths Class A CNC machining Swiss lathes Integrex turning & machining ctr 14” optical comparator CAD/CAM Ultrasonic parts washing Vibratory tumble Machining
  27. 27. PREMIUM CLASS ‘A’ PAINT SYSTEM  11,000-sq-ft enclosed HEPA filter environment  1200’ of conveyor supported from underside of parts using 175 paint racks  Ultra high filtration 5-station wash & rinse system  Color changes <5 minutes  3 Fanuc model 250i paint robots  Electrostatic or HVLP  Infrared/convection curing ovens
  28. 28. PREMIUM CLASS ‘A’ PAINT SYSTEM  HEPA filtered air  Dust & dirt free environment  Underside part support  Reduces scrap generated by standard overhead systems  5-station wash system  Insures clean surfaces  Electrostatic paint system  Ransburg rotary atomizer improves transfer efficiency and final finish quality  Infrared curing ovens  Reduce air movement  Improve first pass yield
  29. 29. SHEET METAL FABRICATION  State-of-the-art soft-tooled fabrication  Complete laser, punching & forming for NPI & production requirements  Product development focus featuring rapid prototype development
  30. 30. SECONDARY PROCESSING  Vibration deburr  E-series press brake  Haeger insertion equipment  Auto-assist silk screening  Wash line  Automated bead blasting  Wet time-savings equipment
  31. 31. SECONDARY PROCESSING  Welding  Metal finishing  Fastening
  32. 32. SHEET METAL CASE STUDY Commercial High-tech Blender 86 unique metal parts Stainless steel construction Multiple gauge materials Riveted assembly Laser cutting/punching Metal forming Hardware insertion
  33. 33. SHEET METAL CASE STUDY Commercial Mail Sorting System 34 unique metal parts CRS, pre-plated, stainless steel Thicknesses range from 18-10 gauge Part size: 2”x2” to 48”x96” Laser cutting/punching/forming Tapping Hardware insertion Welding: Spot, MIG Metal finishing
  34. 34. MACHINING  Milling & turning  Small parts  Parts with long length-to- diameter ratios  Complex parts
  35. 35. DONE-IN-ONE MILLING  Mazak Integrex Mark IV  Turning & machining in a single setup  40-tool capacity  Touch probe tool setter  KM63 dual contact tool connection  2” thru-capacity  LNS Servo 65 bar feeder
  36. 36. CITIZEN SWISS LATHES  Two Citizen A20VII lathes  Seven-axes, 20mm machines  21 tools  C-320 bar feeders  3-20 mm barstock capacity  +0.0000”/-0.0005” precision ground stock  Minimized cycle times via simultaneous main & sub- spindle processes, 32 m/min rapid feed rates
  37. 37. AUXILIARY EQUIPMENT/SOFTWARE  Ultrasonic parts washing  Vibratory tumble deburring  14” optical comparator  Surface finish analyzer  Fully integrated CAD/CAM  Part-Maker -- From solid model to complete 3D simulation to machine G- code (Swiss & Integrex)  MatrixCam – Offline conversation programming (Integrex)
  38. 38. CONTRACT MANUFACTURING  Program management  Global supply management  DFM/DFT  FMEA  Electronic integration & test  Order fulfillment & distribution
  39. 39. PROJECT TEAM Program Manager Supplier Selection / Management Tooling Prototyping Design Order Fulfillment Manufacturing Services Plastic Molded Products Soft Tool Metal Product Assembly Quality & Regulatory Compliance
  40. 40. Mack Technologies Westford, MA Melbourne, FL Juarez, Mexico Mack North Arlington, VT (2) Cavendish, VT Pownal, VT Mack South Statesville, NC Inman, SC Mack Prototype Gardner, MA MARKETS WE SERVE  Medical  Devices  Disposables  Instrumentation  Transportation  Heavy truck parts  Recreation/utility vehicles  Computer & business equipment  Consumer  Defense/aerospace  Energy  Batteries  Solar-powered products  Fuel cell technology  Industrial  Structural HVAC  Furniture & seating  Industrial & building supplies  Lawn & garden
  41. 41. 41 Mack: Company Confidential MEDICAL ACCOUNT SAMPLES
  42. 42. CLEANROOM MOLDING  Class 100,000 molding cleanroom  Installation complete, 12/11  Dedicated to reusable & disposable medical applications  46’ x 44’ modular design  Removable panels to allow for future expansion  Dual air-lock doors, 8’ wide  Rapid roll-up doors  Ease of product flow, tool changes
  43. 43. CLEANROOM PRESSES  Six Toshiba 110-ton electric presses  60% less energy consumption than hydraulic  High-precision machines  Outfitted with high pressure water controllers  More versatility in resin selection
  44. 44. ENVIRONMENTAL MONITORING  Gowns/personal protective equipment required  Particulate airborne monitoring according to ISO 14644-1 standard  Particulate control plan includes:  Alert level  Action level  Ensure compliance with GMPs
  45. 45. WHITEROOM PRESSES  Currently operational  Adjacent to new Class 100,000 molding cleanroom  Engel hydraulic presses  Low-volume, multi-color products requiring quick resin/tool changes  24-hour operation for orthopedic trials, medical disposables
  46. 46. CLEANROOM ASSEMBLY  Class 100,000 cleanroom assembly  30’ x 70’  Non-sterile packaging for medical disposables  Light sonic weld assembly  Temperature & humidity- controlled functional testing
  47. 47. CONTRACT MANUFACTURING  Project management  Supply management  Regulatory compliance  DHF/DMR/DHR management  Design verification  Process validation  Training  DFM/DFT  Order fulfillment/distribution
  48. 48. QUALITY ASSURANCE CONTROL  Quality system  21 CFR 11 & 820 compliant  Electronic DMR & DHR retention  Advanced product quality planning  Process flow diagrams  Risk assessment/pFMEA  Control plans  Dynamic control plans
  49. 49. QUALITY ASSURANCE CONTROL  Component & process qualification/validation  PPAP  IQ/OQ/PQ  Reqs traceability/supplier change controls  Config controls/validated software  Measurement systems  CMMs (3)  Optical systems (4)  NIST-traceable calibration  Gage R&R  Minitab & DataMite  Post-prod risk assessment
  50. 50. DEVICES  Class II/Class III PMA products  FDA registered  Clean room molding & assembly  White room molding  Complaint investigation  Obsolescence management  FRU/kitting
  51. 51. CASE & TRAY SYSTEMS  Custom designs based on OEM requirements  Validated manufacturing process  Plastic, stainless steel, titanium & aluminum  Laser welding  Hermetically sealed weld bead  Free of gas, air, contaminants  JIT stocking arrangements with full lot code  Complete kitting and ship-to distribution services
  52. 52. INSTRUMENTATION  Soft-touch ergonomic handles  Disposable & reusable  Material analysis  Lipid resistant resins  Gamma stable resins  Anti-microbial resins  Autoclaveable ergonomic resins  Overmolding  Insert molding  Final assembly
  53. 53. CASE STUDY Therapeutic Device, Photopheresis Class III PMA device 1,921 total components 616 unique components/80 suppliers 49 subassemblies Dedicated work cell Dedicated product support team 8 functional tests
  54. 54. CASE STUDY Therapeutic Device, Photopheresis Class III PMA device 1,400 total components 358 custom parts/65 suppliers 18 subassemblies Component qualification Dedicated work cell Dedicated product support team 10 functional tests
  55. 55. TRANSPORTATION
  56. 56. ENERGY
  57. 57. COMPUTER & BUSINESS EQUIPMENT
  58. 58. CONSUMER
  59. 59. INDUSTRIAL
  60. 60. Thank You! Copyright © 2011 Mack. All Rights Reserved.

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