mamco sales presentation

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AN ISO 9001 / QS 9000 CERTIFIED COMPANY
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Your Source for Precision Custom
Molded Components.....
Specialists in Insert Molding Automatic loading
systems, reel to reel molding, standard shuttle
and rotary molding machines. Program and Design
Excellence Program Management focused on early
product development. Focus Managing total
quality in all phases of our operation to achieve
and exceed customer satisfaction and
expectations. Technological Systems in Place Cad
Design - Modem, Mold Flow Simulation, Molding
Process Control, SPC, JIT and EDI, Bar Coding,
Full Automation Systems
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MAMCO Vision/Mission
Statement......
Continue to grow....as a World Class, vertically
integrated, precision custom injection
molder....by exceeding all customer requirements
through employee team involvement.
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Mold-A-Matic
Corporation.....
Incorporated in 1964, MAMCO (Mold-A-Matic
Corporation) has grown to become an industry
leader in the development, design, and
manufacturing of precision custom molded
components and assemblies. As a producer of
engineered molded parts and assemblies, MAMCO
utilizes all grades of thermoplastics throughout
their manufacturing process. MAMCOs trained,
motivated and dedicated employees are working
three shifts, five days per week, within a
30,000 square foot facility with 32 molding
presses ranging in size from 15 to 210
tons. MAMCOs first customers were in the
potentiometer industry which required
miniature, close tolerance, molded components.
Today, MAMCO supplies the automotive,
medical, consumer product, telecommunication,
electronics, military and semi-conductor industrie
s. With qualified engineering, quality and
production professionals, MAMCO is able to
embrace the concept of Managing Total Quality
(MTQ) through concurrent engineering, continuous
quality improvements and the guidance of our
established ISO 9001 and QS 9000 standards.
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MAMCO is conveniently located in central New York
between the cities of Binghamton and Albany on
Interstate 88 and 20 miles South of Cooperstown,
home of the Baseball Hall of Fame.
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• Single source procurement for straight and
  insert molded
• components and assemblies.
• High quality, consistent repeatability, complex
  components and
• assemblies.
• Fully staffed, in-house engineering support.
• Sales management with emphasis on continuous
  customer
• support who understands the demands of the
  automotive,
• electronic, military, medical,
  telecommunications, computer
• and consumer product industries.
• A quality program based upon Zero Defects and
  Continuous
• Improvement which emphasizes design for
  manufacturability,
• preventative engineering and advanced planning.
  This led
• to MAMCOs ISO 9001 /QS 9000 certification.

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Annual Sales.....
MAMCO Employees.....
Serving the following industries..
Electronics
Aerospace
Medical
Automotive
Military
Telecommunications
Computer
Consumer Products
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MAMCO Worldwide
Sales Distribution.....
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MAMCO DOMESTIC CUSTOMERS
DELCO ELECTRONICS TRW UT AUTOMOTIVE VISTEON
AUTOMOTIVE TERADYNE CONNECTORS DUNCAN
ELECTRONICS MOUNTAIN MEDICAL ASPEN
LABS CONMED PHILLIPS AIRPAX CLAROSTAT BURNDY
MCT DuPONT HONEYWELL MALLORY CONTROLS
PACKARD ELECTRIC BECKMAN MOSLER LITTON
CORPORATION BLACK DECKER DURACELL EATON
CORPORATION GENERAL ELECTRIC NCR
CORPORATION HAMILTON DIGITAL NEW ENGLAND
INSTRUMENTS THOMAS BETTS IRC ROCKWELL
AUTOMOTIVE SENSORMATIC BREED TECHNOLOGIES CENTUR
Y MANUFACTURING C K COMPONENT 3M TELEDYNE
CORPORATION CTS BOURNS DALE
ELECTRONICS WARNER TECHNOLOGIES AMPHENOL BERG
ELECTRONICS HUGHES POWER PRODUCTS MOTOROLA CORNI
NG, INC TELEX CORPORATION ALLIANT
TECHSYSTEMS VISHAY IBM LOCKHEED
MARTIN AMP RAY-O-VAC GENERAL DYNAMICS SARGENT
ART EXERGEN
INVACARE CORPORATION QA TECHNOLOGIES TYCO AST
ROCOM ELECTRONICS CHERRY AUTOMOTIVE DELPHI /
DELCO HARLEY DAVIDSON
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MAMCO FOREIGN CUSTOMERS
AB - ENGLAND AB - GERMANY HELLA PHEH
RUF VDO SPECTROL VISHAY -
ISRAEL BOURNS PHILIPS - HOLLAND
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AUTOMOTIVE CUSTOMERS
DOMESTIC DELCO ELECTRONICS TRW UTA DELPHI R
OCKWELL AUTOMOTIVE VISTEON AUTOMOTIVE BREED
TECHNOLOGIES DUNCAN ELECTRONICS EATON
CORPORATION 3M AMP CTS BOURNS DALE
ELECTRONICS
ABROAD AB - ENGLAND AB -
GERMANY HELLA PHEH RUF VDO SPECTROL BOURNS

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• PRECISION COMPONENTS UTILIZED WITHIN

MULTI-FUNCTION SWITCHES
INSTRUMENT CLUSTER COMPONENTS
(VISUAL AND NON-VISUAL)
ELECTRONIC DOOR CONTROLS
THROTTLE POSITIONING SENSORS
TRANSMISSION TEMPERATURE
SENSORS
SEAT BELT COMPONENTS
POWER SEAT AND HEAT SWITCHES
AIR BAG SENSORS
HEAD LAMP SWITCHES
AIR/FUEL SWITCHES
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Process Capabilities....
Capabilities Original
Designs Mold-Flow Analysis Design FMEA
Design Optimization Customer Process
Integration Process FMEA Advanced
Quality Planning (APQP) Statistical Process
Control Application Testing
Capabilities Short Run Prototypes High Speed,
Precision Dies Multi-Cavity Molds Automated
Assembly Systems
Semi or Fully Automation 100
Visual Inspection Vision Systems
Attribute Checking Custom Testing
Automated Packaging Tolerances gt .0005
In.
Capabilities Material All Engineering
Grades of Thermoplastics Size 1
Oz. to 4 Oz. 15 to 90 Ton 13 Oz.
210 Ton
Capabilities Wire Brushes, Plastics, Screw
Machine Parts, Castings, Varsities, Wire Forms,
Capacitors Decorative Appliqués
Capabilities Material
Base to Precious and Bi-Metal
Capabilities Reel to Reel Tube Tray Strips Piece
Parts, Bulk
Assemblies
Secondary Operations Automation Systems Post
Mold Operations Hot Stamping Pad Printing
Forms of Assembly Custom To Meet Your
Requirements
Ship to Customer
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Quality Policy
Statement.....

• Policy
• The management and employees of Mold-A-Matic are
  committed to manufacturing
• products that conforms to customer requirements
  and specifications. This
• commitment is reflected in the following quality
  objectives
• In the spirit of teamwork and cooperation with
  our customers, MAMCO will
• produce a quality product.
• MAMCO will maintain a formal quality system
  meeting and or exceeding all
• QS 9000 quality system requirements.
• MAMCO will foster an atmosphere for continuous
  improvement in all phases
• of operations while focusing on our Zero
  Defects Program and PPM goals.
• MAMCO will communicate our quality policy and
  objectives to all employees.
• MAMCO will continue to develop relationships
  with our customers and
• supplier base that emphasizes continuous
  improvements.
• MAMCO will empower employees so they can help
  improve the
• systems that effect their work.

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Quality/Process
Improvement Plan.....
MAMCO has been actively involved with a Zero
Defects Program since 1981. Through this
philosophy and world class manufacturing
concepts, we are striving for perfection in every
aspect of our business. MAMCOs commitment to
Managing Total Quality involves all MAMCO
personnel. Our focus is to achieve total
customer satisfaction through continuous quality
improvements and gain preferred supplier
status. MAMCO will maintain and update our
procedures as we work with new suggestions,
methods and technologies associated with
continuous improvements. This outline will be in
accordance with QS 9000 specifications.
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Quality Improvement
Plan.....

• MAMCOs dimensional SPC procedures will
  facilitate process and
• capability improvements.
• MAMCO will track and maintain PPM levels with
  an ultimate goal of
• Zero PPM for all customers.
• MAMCO will constantly work on all programs to
  establish automatic
• checks and systems to prevent the
  manufacture of visible and
• subjective discrepancies. This will be
  accomplished by utilizing at
• the process Vision Systems, Visual CMM
  equipment and custom
• testing automation.
• MAMCO has established a goal for having all of
  our suppliers
• certified to ship to stock and do so in
  accordance with QS9000
• specifications.
• MAMCO is utilizing APQP and Design / Process
  FMEAs to analyze
• potential failures, effects of failures,
  seriousness of failures,
• probability of occurrence and detection,
  current controls
• and will recommend an action plan based on
  these analysis.

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Quality
Indices......

• New Mold Requirement Reports
• In-Process Cost of Quality
• Fallout Efficiency Reports
• PPM Reports
• Corrective and Preventive Procedures
• Non-Conforming Material Reports
• Discrepant Material Reports
• Internal Rejections
• Customer Complaints/Returns
• On-Time Delivery Monitoring
• Supplier Indexes based on

• Quality

• Responsiveness

• Delivery

• Cost

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Corrective
Actions......

• MAMCO uses the customers forms when supplied
• or our own 8d format.
• MAMCO uses CITI forms for internal
• improvements and corrections.
• MAMCO also provides our suppliers with a
  specific
• form to be completed for all discrepancies.
• Finally, MAMCO has our non-conforming material
• reports that drive corrective action on the
• production floor.

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Time
The end result is a optimized part, designed for
manufacturability, which will travel through the
entire process in the least amount of
time. MAMCO embraces early involvement through
concurrent engineering!
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• MoldFlow Part Adviser (Injection Molding Process
  Simulation Software)
• Moldflow Part Adviser enables a quick evaluation
  of molded plastic parts for manufacturability.
• Moldflow Part Adviser provides reliable
  answers to key design questions in minutes,
  working directly from the CAD solid model.
• Design concepts are quickly tested and modified
  at the early stage when the cost of change is
  minimal.
• The Part Adviser provides advice on the
  confidence of fill, injection pressure, pressure
  drop, flow front temp, fill time, fill pattern,
  weld lines, and air traps. Results are printed
  in color plots and recorded in windows .avi
  animation files.
• Produces results in minutes and displays them
  directly on the solid model.
• Over 4000 materials in the Moldflow database.

• Solidworks 2005 ( Mechanical Design Software)
• Creation of solid models.
• Solidworks imports solid model files in XMT,
  IGES, STEP, DWG, and DXF.
• Operates on Microsoft Windows platform.
• Engineering e-mail address bob_at_mamco.net

If developed in Transfer as.. Through..
Solidworks .SLDPRT E-mail
Unagraphix Parasolid .XMT
SDRC .IGES flavored format for UNAGRAPHIX with trimmed surfaces.
Catia .STEP
Proengineer Parasolid .XMT
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Mold-A-Matic
Principles.....

• Utilize a strong and
• experienced group of
• technical engineers with
• expertise that includes
• designing, automation, quality
• systems and who grasp the
• emphasis on concurrent
• engineering and continuous
• quality improvements.
• Manage a worldwide staff of
• sales professionals who
• understand the intricacies of
• each market in which we
• operate.

• Offering full product and
• process development services.
• In-house mold maintenance
• with prototyping capabilities.
• Utilize statistical process
• control (SPC) to maintain our
• operating systems and
• determine process capability.
• Ensure quality is
• manufactured into all products
• base all procedures on ISO and
• QS 9000 requirements.
• Develop specific production
• plans, customized to your
• quality, delivery and packaging
• needs.

• Incorporating advanced
• quality tools such as Design
• and Process FMEAs and
• Mold Flow Simulation to
• ensure optimized mold and
• process development.
• Continue the pursuit of
• developing our employees
• through training and
• production teams. Ensure all
• employees understand the
• customers requirements.
• Assign each customer account
• to an account executive for
• personal and individualized
• attention.

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Partnership.....
MAMCOs desire to form a partnership with a
customer can only be effective when both parties
function as one and in the best interest of the
other.

• The key ingredients to this philosophy are
• Trust
• Honesty
• Enthusiasm
• Open Communications
• Concurrent Engineering

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Points of Consideration of a Mold
Design and Determining Factors.....

• Gate and Runner Size
• and Design
• Material to be Molded
• Dimensions of Part
• Shape of Part

• Ejecting Part from Cavity
• Ejector Pin Location
• Possible Draft of Cavity
• Part Distortion

• 1. Type of Mold
• Material to be Molded
• Production
• Size of Part
• Dimensions
• Inserts in Part
• Shape of Part
• Machine Availability
• and Size

• Shrinkage of Material
• Past Experience
• Material Manufacturers Literature
• (Approx.)
• Size of Part
• Type of Mold
• Uniformity of Part
• Location of Gate or Sprue and Size
• of Gate
• Insert in Part
• Molding Techniques (Perform,
• Cure, Pressure, etc.)
• Material Flow (Soft,
• Hard, etc.)
• (j) Design of Mold

• Gate Location
• Dimensions of Part
• Shape of Part
• Appearance
• Ease of Removal

• 2. Number of Cavities
• Production
• Size of Part
• Dimensions of Part
• Inserts in Part
• Machine availability
• and Size
• (f) Cost of Parts

• Ease of Cavity Correction for
• Critical Part Dimensions

• Location of Split Line
• Appearance
• Ease of Cleaning
• Dimensions of Part
• Noted on Part Print

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Points of Consideration of a Mold
Design and Determining Factors.....

• Mold Base Selection
• Type of Mold
• Type of Machine to be Used
• Molding Pressures Needed
• Cavity Layout
• Type of Mold Heat

• 9. Type of Cavity Construction
• Solid (Machined, Electrical
• Discharge)
• Solid (Hobbed)
• Laminated
• Cast (Copper, Filled Epoxies, etc.)
• Plated Nickel and Copper
• Combination of Above

• Side Draws
• Loose Block
• Pull Pin
• Air Hydraulic

• Removable Solid Cavities
• Production
• Ease of Loading Inserts
• Cycle Time
• Multiple Inserts
• Repair of Cavities

• Type of Mold Heat (Oil,
• Steam, Water, Electric, Platen
• or Cooling
• Temperature Required for
• Molding Specified Material
• Size of Mold Base
• Type Available at Press
• Accuracy of the Heat Needed

• Steel Selection, Heat Treat
• and Plating
• Production
• Material to be Molded
• Molding Pressures
• Design Cavity Details

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Molding Definitions..
Injection Molding Method of forming plastic to
the desired shape by forcing the heat soft-end
plastic into a relatively cool cavity (tool
mold) under pressure
Thermoplastic Injection Molding A process of
thermoplastic polymers in which melted plastic is
injected into a mold cavity, where it cools and
takes the shape of the cavity, bosses, screw
threads, ribs, and other details can be
integrated, which allows the molding operation
to be accomplished in one step. The finished part
usually does not require additional work before
assembling.
Insert An integral part of a plastic molding
consisting of metal or Other material that may
be molded into position during the
molding Process.
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Molding Definitions..
Cycle Time The total time required from shot to
shot.
Flash The portion of the charge which flows from
or is extruded from the cavity during molding.
Draft A taper on the side wall or core pin of a
cavity to facilitate removal of the molded
article from the cavity.
Flow Mark A visible mark resulting from the
solidification of a pattern flow
Force The part of the mold that transmits the
pressure of the press to the top of the molding
charge, for the material into the cavity.
Ejector Pin A pin used to remove the molded
article from the cavity.
Gate A restriction in the runner at the point
where the runner Enters the cavity
Pin The part of the flash that is attached to the
molded Article.
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Molding Definitions..
Air Vent A groove in a mold which allows the
trapped gases in a cavity to escape.
Core Pin A pin used to form a hold in the molded
piece.
Cores That portion of the mold that forms
the required inner surface of the molded article.
Cavity The portion of the tool that contains the
opening for producing the desired shape and/or
that area of the opening that forms the outer
surface of the molded article.
Cull The material remaining in the transfer
pot after the mold is filled.
Cold Slug Well A space at the end of a runner or
sprue to hold the cold slug and prevent it from
entering the cavity.
Cure of the Clamp Time The time the mold is
closed to allow the complete chemical change of
the material of the material to take place and/or
allow the material to harden enough for ejection.
Core Lines The holes in the mold base and/or
cavity through which passes a suitable liquid or
steam to maintain the proper mold temperature.
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What is Plastic?
Definition of Plastics (Society of Plastic
Engineers) Any one of a large varied group of
materials Consisting wholly or in part of
combinations of carbon with oxygen, hydrogen,
nitrogen, and other Organic and inorganic
elements which, while solid in the finished
state, at some stage in its manufacture Is made
liquid, and thus capable of being formed into
various shapes, most usually through
the Application, either singly or together, of
heat and pressure.
In more technical terms, plastics have the
following

• Synthetic Material That is, a material that is
  produced by man in the laboratory and not
  generally found in nature Nature has provided
  the ingredients, but it took man to combine the
  certain natural elements in order to synthesize
  plastics.

• Organic Compounds Organic compounds are those
  that contain carbon they are the compounds that
  have carbon to carbon linkage of atoms in there
  structure.

• Processability The plastic material must be
  able to flow at some stage before it becomes a
  finished product the material must be capable of
  being formed, shaped or molded.

• Polymerization A plastic material is a
  polymerized substance. Polymerization is the
  combining of two high molecular weight organic
  compounds under heat or pressure or both, to form
  a larger molecule having different
  characteristics than the original molecules.

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Material Properties..
Specific Gravity The ratio of the weight of a
given volume of material to that of an equal
volume of water.
Molding Shrinkage Inches per inch the
differences per unit of a molded part, cold, and
the cold mold.
Bulk Factor The ratio of the volume of the
non-performed molding material to the volume of
the molded part.
Water Absorption The quantity of water absorbed
by a given test specimen for a predetermined
period of time at a constant temperature
expressed in percent gain.
Plasticity or Flow The capability of a molding
compound to fill a mold under prescribed pressure
and temperature.
Co-efficient of Linear Thermal Expansion The
ratio of the change in length of a specimen per
degree C to its length at 0 degree C.
Impact Strength Izod (Ft/lb. Per Inch of
Notion) The energy required to break a standard
notched specimen.
Heat Distortion Temperature (F) at Fibre Stress
of 66 and 264 PSI The temperature required to
permit an arbitrary standard amount of deflection
by a standard load.
Tensile Strength PSI The force required to
break a given test specimen.
Compression Strength PSI The measure of
compressive load to cause failure.
Heat Resistance F The temperature to which a
part, under load, can continually operate without
change in physical dimensions.
Flexural Strength PSI The maximum fibre stress
sustained by standard test specimen, calculated
from the bending load required to break.
Deformation Under Load (Cold Flow) Dimensional
change under a constant load at a given
temperature.
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Material Properties..
Modulus of Elasticity in Tension PSI The
measurement of a force required to produce a
given change in dimension.
Arc Resistance Seconds The measure of the time
required to produce a conductive path between two
electrodes to the total current between them.
Abrasion Resistance The ability of a material to
withstand mechanical action such as rubbing,
scraping, or erosion. Expressed in volume lost.
Insulation Resistance MegaOhms Volume and
Surface Resistance The ratio of the direct
voltage applied to two electrodes to the total
current between them
Rockwell Hardness Resistance to penetration from
a standard load applied to a spherical ball for a
standard length of time.
Dielectric Constant The ratio of the equivalent
parallel capacitance, measured at a specified
frequency of a capacitor in which the material is
the dielectric to the capacitance of the same
capacitor with a vacuum, or air, as the
dielectric.
Durometer Hardness A, B, or D Scale The degree
to which a specimen can be indented under
constant load by an indentor of fixed dimensions
Light Transmission Percent The measurement of
the percentage of luminosity transmitted through
a solid material.
Dielectric Strength VPM (Short Time
Step-by-Step) The average root-mean-square
voltage gradient between two electrodes at which
electrical breakdown occurs under prescribed
conditions.
Flammability The length of time, in seconds, a
material will burn for a prescribed distance,
after removal from the source of flame.