PDI’s Continuous Improvement Initiative & Training

By Dan Gish, Director of Quality, PDI

The primary focus of the business for the past several years has been on building a “Better Mouse Trap”. Our Improvements to product Quality and Manufacturing throughput are a significant part of how we maintain our competitive edge. By placing the focus on individual jobs and determining what is critical to quality, as well as, identifying the opportunities we have to increase efficiency, are how we created this recipe for success.

PDI Management is dedicated to the continuous improvement initiative. They have invested greatly in the manufacturing facilities, equipment, and processes over the years. The focus now is on the Continuous Improvement of our work force through education and training.

A couple of months ago, at the Plastic Designs Connecticut Facility, a Certified Six Sigma Trainer was brought in to perform an overview for the Management personnel. Over the past 2 months this trainer has conducted two, Six Sigma for Plastic Injection Molders workshops.

“This Six Sigma concept is not ‘just’ about Statistical analysis of data; it is a mind set and a business motivator to maximize business success thru continuous improvement. This is the path we are continuing on.”

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Plastic Design International was started in 1977 in the short-run prototype R&D business. PDI is now one of the most effective Plastic Injection Molding production companies on the East Coast and an expert Mold Making manufacturer. Please contact us with any questions at 860-632-2001.

PDI Happenings - Smart Choices in Todays Economy

Smart Choices

By Steve Everett, Manufacturing Manager, PDI

At PDI, our management team sat down some time ago and developed a strategic plan. One large part of this plan was to invest in new equipment for our molding department. After months of research and testing we realized the smart thing to do was to upgrade to electric molding machines.

We were one of the first companies in CT to purchase an electric press using the Connecticut Energy Efficiency Fund. With the help of CL&P (our electricity supplier) and the supplier of the molding machines, we were able to begin purchasing machines that were more economical and could run with better accuracy than the older hydraulic machines of the past. The initial cost of the electric machines is higher than a new hydraulic machine, but CL&P offered a rebate program and we were able to use that money as a deposit on the new electric machine. Also, we would realize a savings of electricity which would virtually pay for the machine over time.

Here is an example of one job that PDI is able to run more efficiently due to utilizing electric presses. We had a mold that ran 4 days a week, 24 hours a day at a 21 second cycle, it needed an operator 100% of the time, ran in a 2 year old hydraulic machine and we were getting occasional quality dings for the parts. We moved this job to our new electric machine and with no changes to the mold we were able to drop the cycle to 18 seconds and eliminate the labor of inspecting each part reducing it to a quality check every 2 hours, so the parts now just need a conveyor and a box to run. After 6 months we had shipped to our customer with zero defects.

Today PDI proudly uses 14 electric molding machines. We have also invested in sprue pickers and boxing conveyors. We have focused on taking labor out of running our parts, making us globally competitive.

Another part of our strategic plan involved taking advantage of a program offered by CL&P where they replaced all of our factory lighting with “high effect” lighting. We also installed a high efficiency chiller system for our molding department, taking advantage of the 2008 CL&P energy program.

PDI continues to look ahead to the future and plan wisely. With the high cost of energy and the challenges with the economy we are making the smart choices to be sure we are here far into the future and will be able to give our customers the best value for their dollar.

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Plastic Design International was started in 1977 in the short-run prototype R&D business. PDI is now one of the most effective Plastic Injection Molding production companies on the East Coast and an expert Mold Making manufacturer. Please contact us with any questions at 860-632-2001.

Quality Capabilities

• ISO9001 Registered
• “PPAP” Program = APQP, PFMEA, Quality Control Plans, etc…
• First Article Inspection Report
• Statistical Process Control
• Capability Studies
• Process Validation Studies
• Fully documented inspection plans and procedures
• ERP System Software
• Job review, and process set-up controls
• Document control
• Continuous improvement program
• Corrective & Preventative Action System
• Non-Conforming Material/Tool control
• Documented shipping Instructions
• Calibration Control System
• Internal Auditing Program
• Our Quality Department is fully equipped with the latest measuring devices including:
• Coordinate Measuring Machine (CMM) & Optical Measuring Machine…
• Regulatory Compliance Program

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Plastic Design International was started in 1977 in the short-run prototype R&D business. PDI is now one of the most effective Plastic Injection Molding production companies on the East Coast and an expert Mold Making manufacturer. Please contact us with any questions at 860-632-2001.

Plastic Design Quality Management System

ISO 9001-2000 Registered: PDI has an established and maintained QMS that is driven by our continuous improvement initiative. Our commitment to best practices for improving the quality of our products, processes, and business partnerships are * what has made us an icon in our industry. *Or, what has made PDI / our business operations a success….

Product Realization: As a supplier of Automotive, Fire Safety, Security Systems and Defense Industry products, to name a few, we have adopted QS / TS Quality tools for our everyday operations. From the PPAP kick off of the Advanced Product Quality Planning meeting 1, with our customer participation to establish what is critical to quality, through to the customer part approval process.

Process Control: Plastic Design has proven systems for Validating and Sustaining our products and processes. These are the key to maintaining the Quality our customers demand. We have Manufacturing visibility and materials traceability throughout the organization. This is achieved by using ERP Software that is a comprehensive operations management, distribution, and financial management tool set. Maintaining and Monitoring is achieved through our comprehensive; operation sheets, production & quality work instructions, mold and machine maintenance, and surveillance auditing. All these processes enable us to consistency produce quality products.

Regulatory Compliance: Global regulatory compliance is a necessary part of our business environment. PDI operations comply with the RoHS directives. We maintain an internal compliance system for Certificates of Compliance, RoHS and WEEE Compliance, and Material Composition Declarations IPC 1752-1.

Supply Chain Management: Development of suppliers is a critical aspect of achieving a consistent product. The foundation of any quality product starts with the quality materials going into it. ----------------------------------------------

Plastic Design International was started in 1977 in the short-run prototype R&D business. PDI is now one of the most effective Plastic Injection Molding production companies on the East Coast and an expert Mold Making manufacturer. Please contact us with any questions at 860-632-2001.

Mold Making Capabilities

Mold Making Capabilities

Our experienced tooling department personnel use their decades of combined experience to ensure the most precise tooling results available. For plastic injection tooling and prototyping applications, we meet your quality demands as well as those of your customers.

• Prototype & Multi-Cavity High Production Tools
• Domestic Tooling
• Asian Tooling
• Proficient and Highly Skilled Tool Design
• Hydraulic Core pulls, cam activated, unscrewing
• 3D Machining / CNC
• EDM
• Quick Turn-around Mold Changes
• Mold Sampling and Evaluation
• Production support/maintenance
• Engineering changes – design & implementation
• Innovative fixturing
• Solidworks

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Plastic Design International was started in 1977 in the short-run prototype R&D business. PDI is now one of the most effective Plastic Injection Molding production companies on the East Coast and an expert Mold Making manufacturer. Please contact us with any questions at 860-632-2001.

Plastic Injection Molding Capabilities

Our experienced tooling department personnel use their decades of combined experience to ensure the most precise tooling results available. For plastic injection tooling and prototyping applications, we meet your quality demands as well as those of your customers.

• Prototype & Multi-Cavity High Production Tools
• Domestic Tooling
• Asian Tooling
• Proficient and Highly Skilled Tool Design
• Hydraulic Core pulls, cam activated, unscrewing
• 3D Machining / CNC
• EDM
• Quick Turn-around Mold Changes
• Mold Sampling and Evaluation
• Production support/maintenance
• Engineering changes – design & implementation
• Innovative fixturing
• Solidworks

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Plastic Design International was started in 1977 in the short-run prototype R&D business. PDI is now one of the most effective Plastic Injection Molding production companies on the East Coast and an expert Mold Making manufacturer. Please contact us with any questions at 860-632-2001.

Bringing Innovation to Plastic Applications

Plastic Design International (PDI) has been providing custom plastic injection molding solutions for over 30 years for companies whose plastic products and components require critical tolerances and exacting specifications. Our team of experts works closely with each customer, focusing on their unique needs, to find the global plastic solution that is the best match.

We exceed our customer’s expectations every time by:

• Providing high-quality molded products: Plastic Injection Molding Capabilities
• Creating mutually beneficial partnerships with our customers and suppliers.
• Providing innovative, customized solutions for our customers’ plastic needs: Mold Making Capabilities
• Keeping abreast of the latest technological innovations.
• Utilizing best-in-class manufacturing practices: Plastic Designs Quality Management

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Plastic Design International was started in 1977 in the short-run prototype R&D business. PDI is now one of the most effective Plastic Injection Molding production companies on the East Coast and an expert Mold Making manufacturer. Please contact us with any questions at 860-632-2001.