The Challenge

As part of the FLEXAN LLC family of medical device manufacturing companies, MEDRON specializes in product development, design for manufacturability, and production of thermoplastic molded and extruded components. Our customers are in the top 100 of medical device OEMs worldwide. Over the years, we have supported a wide variety of projects for our customers. During a recent project, we faced molding inconsistencies due to resin variability from lot to lot. We also wanted to optimize our insert molding process and maximize throughput of automatic injection molding processes. We had explored operator training, requiring tighter resin specifications, changing mold designs, and more. Some of these items improved results, but not to the extent we were looking for.

The Solution

We first heard about RJG from other colleagues in the injection molding industry and decided to start working with them in 2013. After our engineers completed the RJG Systematic Molding training, we decided to implement Decoupled II molding techniques in process validations for new products. We opted for RJG’s training because it was highly recommended by others who had completed it. It was a good fit for us because it was on-site, only one week, and the trainer was very knowledgeable. We were able to participate in several demonstrations and activities, which made it more interactive and memorable.

The Result

Our first indication of increased quality and cost savings was the significant increase in throughput. We are now able to make more than twice as many parts in the same amount of time—one process part output increased from 16,000 to 40,000 parts per day. Our scrap rates have also decreased significantly since implementation. We now have a more robust injection molding process that is less sensitive to resin lot to lot variability thanks to Decoupled II molding. We are interested in learning about the benefits of other RJG equipment and will evaluate a plan for implementation. RJG products and training provides our customers with better on-time delivery, better part quality and consistency, and allows us to better meet product growth needs.

Christopher Weaver
Project Engineer
FLEXAN LLC / MEDRON LLC

About MEDRON LLC

MEDRON LLC, now part of FLEXAN LLC, is a recognized leader by global medical device OEMs for its strength in product development and design for manufacturability. They manufacture numerous life-saving medical device assemblies in addition to other outsourcing services including, high-volume manufacturing, customer private label capability, and thermoplastic extrusion services.

The Challenge

As a MedTech Molder, we utilize multiple high precision molded parts in our assembly automation cells to produce the final medical product that needs to be shipped to stock at the original equipment manufacturer. We needed to minimize the cost of scrap on a high dollar finished device—just one bad part out of a 12-component assembly can cost a lot of money. There is no rework.

In order to address this challenge, we tried standard methods of sticking to the process run sheet set points from run to run. We also implemented the use of the process monitoring features on the machine to identify possible variations. Though the results were good, we always seemed to be chasing something on the higher precision parts with tighter process windows. This was in part due to following traditional process developments instead of a systematic molding approach.

The Solution

In 2001, Doug Thorpe, then a Nypro Project Engineer, attended a local Executive Overview with Rod Groleau, founder of RJG. Thorpe quickly completed RJG Master Molder I and II as well train the trainer. I was a student in Thorpe’s first class at Nypro’s Learning Center in 2003 and became a certified trainer in 2007.

We were so enlightened and recharged by our experience in the course, we decided to continue training our workforce through RJG. All of our technical resources, as well as non-technical, are encouraged to attend some level of RJG training in order to develop a common understanding of the challenges we face as a MedTech (and packaging) injection molder / assembler.

After an initial 15-machine trial in 2004, we have since outfitted our entire fleet of machines with eDART® Systems. We have now been working with RJG for over 10 years, for both training and technology. In that time, we standardized on cavity pressure sensors where applicable and learned a ton as a team. It has been a learning curve to get to where we are today, but it has grown into part of our culture.

The Result

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. We have standardized the use of systematic decoupled molding process development and implemented the use of cavity pressure technology part containment. RJG’s technology also allows us to measure and reduce cavity-to-cavity variation.

Utilizing RJG’s technology gave us the ability to see inside the process and understand what was going on. The eDART graphs allowed us to see the interaction of the press and cavity at the same time with respect to plastic pressure. 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
Manufacturing Engineering Manager
Nypro Healthcare, Clinton / Devens

About Jabil

Jabil is a product solutions company providing comprehensive electronics, design, production and product management services to global electronics and technology companies. Offering complete product supply chain management from facilities in 29 countries, Jabil provides comprehensive, focused solutions to customers in a broad range of industries.

The Challenge

The main problem for us is standardization—keeping a consistent process and a step-by-step guide to get the process back. The lack of both bring big repercussions to the quality of the final product. Customers require a lot of information on the quality evaluation, which can be difficult to gather and sometimes proper documentation doesn’t even exist.

The Solution

I heard of RJG from my boss four years ago and attended a Systematic Molding for Liquid Silicone Rubber course in 2015. It was eye opening to learn how to handle the process from the plastic’s point of view, and I learned that we can have standardized steps to get the process back. I continued onto Systematic Molding and obtained my Master Molder® I (MMI) certification in 2017.

The Result

Since my training, the process has improved both in silicone and plastic injection, and I have a better understanding of the process and improvements that can be made. The first indication of return on investment was the cycle time improvements, followed by the definition and standardization of the molding process and quality improvement.
Nowadays, our silicone process is the most stable at our facility. If a problem arises, I can get a process back in less than thirty minutes. One of my main takeaways from training is to document everything. Coming back from MMI, I parametrized every machine and mold using the process and tests I had learned. After testing four molds, I discovered that the process was set up incorrectly. These tests lead to developing an improvement initiative that will save our company half a million dollars annually.

The three consultants who have worked with me throughout my training path have provided me with the confidence to handle my own process. Their support when I reached out to them in each moment of doubt has been great. We plan to continue working with RJG in the future, including participating in their Master Molder® II program. RJG’s method of training made a huge impact on our company and will continue to make a difference in the industry as a whole.

Jose Bando Huerta
Mechanical Process and Molding Engineer
Robert Bosch Sistemas Automotrices SA de CV

About Bosch

Bosch is a global leader in the electronic industry. Our facility in Cd. Juarez Mexico is currently serving leaders in the automotive industry by providing high quality, high precision plastic and silicone injected parts. Bosch began operations in Mexico in 1955, importing for the local automotive, electrical, and diesel products—both aftermarket and original equipment. Since then, Bosch has been involved in industrial development and contributes to the growth of Mexico.