Productive Plastics is a leading plastic thermoforming manufacturer. With ISO 9001:2008 registration, UL certification, and Lean/TPS, Productive Plastics is able to offer the highest quality products and services for its customers. Founded in 1955, Productive Plastics works in a close and proactive partnership with its customers to provide them with the best possible thermoformed plastics solutions for their specific needs.
In 2009 Productive Plastics received a NJDOL training grant and needed training and implementation support to achieve its objectives — improving its operations through the application of Lean manufacturing techniques and equipment training. Hal Gilham, the company’s president, was in the process of relocating its Sensigraphic operation into Productive Plastics’ facility and wanted to be assured the results would be effective and efficient. Productive Plastics has a history of working with NJMEP and achieved positive results in reducing equipment downtime, as well as other projects. So… when Gilham needed assistance, he turned to NJMEP again.
Productive Plastics became an early leader in pressure thermoforming. 1985 saw the advent of programmable, CNC routing and, true to the company’s tradition of innovation, Productive Plastics geared up for use of a multi axis manufacturing process, one which enabled these significant advantages: greater accuracy and repeated secondary operations.
Gilham knew that training his employees in ever-changing technologies would be key to maintaining his company’s position in the industry.
Two projects, Lean Layout Process and Technology Training, were implemented to ensure Gilham would meet his objective of improving operations.
To assure the integration of Sensigraphic produced the desired results, NJMEP provided Productive Plastics with cellular plans and layouts along with a line balancing plan for optimum efficiency and through put in the operation.
NJMEP resources were brought in to deliver advanced training on the CNC router and the FaroArm®, which is portable measurement device that allows manufacturers to easily verify their product quality by performing inspections, tool certifications, CAD-to-part analysis, and reverse engineering. The device provides factory floor measurement up to 12′ range and from .0009″ accuracy.
The CNC training program encompassed a total of 80 hours of Customized CNC training, conducted on-site, for the operators. The program included: the Basics of CNC, Axis and Motion, Methods of programming, Cutter Compensation, on and off line programming, operation, safety inspection and troubleshooting.
The FaroArm® Training consisted of: Equipment overview to include terminology, calibration, linear measurements; measuring in constrained state for complex measurements, projecting surfaces, true position and other GD&T function; measuring to a CAD model to include alignment, Leap Frogging for large parts and a course review that included Q&A.
The NIST survey results indicated that as a result of these projects Productive Plastics achieved $150,000 in new sales, retained $650,000 in sales that could have been lost, and overall realized a cost savings of $167,000.
When asked, Hal Gilham, President, Productive Plastics, explained, “NJMEP is a trusted advisor and continues to support us with knowledge, expertise and direction. In the past, with their help we succeeded in updating our web presence, which as a result has increased our sales and more recently we improved our CNC and FaroArm® technology. NJMEP came through for us one again. They provided excellent resources when other providers could not; their field agent mentoring of our strategic endeavors provided a bold and fresh approach for our business. We are continuing to count on NJMEP for their leadership, creativity and results for our business and look forward to working them on our lastest endeavor” .
Productive Plastics, Inc. is a participant in NJMEP’s Made in New Jersey program. Click here to view their profile!