PRWPLASTICS INDUSTRY AWARDS 2012 19

28 September 2012 ● Read more online at www.prw.com

Supplier Partnership – Prime MachineryWinner: Arburg –John GuestWest Drayton-based push-fit connector manufacturer John Guest undertook a challenging project with injection moulding machine supplier Arburg. The component was a critical, complex moulding, with exceptionally high tolerance demands leading to a greater scrap rate than normal.

The part’s geometry required a secondary turning operation after moulding to improve functionality. This was labour-intensive, costly in waste material, and restricted the workflow of the component, prolonging manufacturing turnaround. John Guest had to hold greater than normal levels of work-in-progress to ensure that customer demands were met.

The project began by determining how to redesign the tooling to allow for the component to be run fully automatically with zero quality defects and without

the secondary operation.The second step was to establish the screw

and barrel configuration offering the best combination of residence time, utilisation of shot weight and energy consumption.

The third step was to analyse which machine from the Arburg portfolio would offer

the best price/performance ratio for John Guest.The mutual commitment of both companies

concluded the project successfully with significant benefits for John Guest. Cycle time was

significantly reduced and the secondary manual operation was eliminated. An innovative tool redesign led to a sizable saving in material. The hybrid (electric/hydraulic) technology of the Arburg Hidrive machine adopted reduced process energy consumption and the overall manufacturing time for the completed assembly was cut by more than a third.

These measures contributed to substantial cost savings in making the part, allowing John Guest to remain competitive in its manufacture in the UK, and retaining the high quality on which the company’s reputation is based.

A PIA judge commented: “This was an exception-ally professional project with great outcomes.”

fi nalistsEngel UK/Becton Dickenson DiagnosticsEngel UK partnered Becton Dickenson Diagnostics (BDD) in finding a higher-output solution for injection moulding BDD’s principal product – blood collection tubes. With no additional factory floorspace available and an especially tight straightness tolerance on the part, conventional ways of improving cycle time were precluded. These challenges were addressed by an innovative mould configuration. Cavitation was increased, cycle time was substantially reduced, and annual output was more than doubled, using a moulding machine size and floor area similar to previously.

KraussMaff ei (UK)/Bio Pure TechnologyWaterlooville-based Bio Pure Technology (BPT) set up an operation to manufacture its own range of plastic bio-disposable products. The company selected KraussMaffei (KM) as a partner from a shortlist of three major injection moulding machine manufacturers. KM provided full technical support in designing and laying out a new moulding suite, and committed to supporting BPT with design concepts for the forecast growth of the com-pany’s business.

Netstal – MGS Manufacturing GroupWhen MGS Manufac-turing won a contract to supply a printer cartridge case mould-ing, Netstal supported the company in meeting the challenge of adapting an

existing automated moulding cell to run with a new EVOS 3500 Hybrid machine. Production began on schedule just eight weeks after transfer of the mould and cell from the previous contractor.

Netstal/United Closures & PlasticsNetstal supplied injection moulding plant and technical support for three projects undertaken by Bridge of Allan-based United Closures & Plastics (UCP). Increased volume demand from a customer required UCP to invest in new tooling and machinery for a metal cap protection carrier for automatic beverage bottling. A Netstal machine increased throughput by half, using the existing mould. Following this success, Netstal worked with UCP on product design and a complete production cell for a non-return device for spirit bottles. Finally, Netstal helped develop a process to metallise plastic bottle caps, enhancing aesthetics and reducing manufacturing costs..

Sumitomo (SHI) Demag – MolexMolex, a global supplier of intercon-nect products, was looking to help a customer create a multicomponent 2-shot connector for a new energy-efficient central heating water pump. The equipment would require a range of unique elements, all of which would prove challenging to manufacture. After extensive research and proposals, Sumitomo Demag was able to provide the solutions to these challenges. A highly complex project, Sumitomo Demag’s partnership approach achieved all the required goals and at the same time helped raise its customer’s profile in a new market.

GTMA in association with the Manufacturing ResourceCentre specialises in offering a confidential, free, fastand efficient service to all industry sectors to supplycompetent, qualified engineering companies from oursupply chain of GTMA companies.

Address: GTMA | National Metalforming Centre |47 Birmingham Road | West Bromwich | B70 6PY

t: 0121 601 6350 email: admin@gtma.co.ukWebsites:

www.gtma.co.uk www.manufacturingresourcecentre.co.uk

UK MANUFACTURING

Photos courtesy (l to r) top: Erodex, Bayer Healthcare, Nissan, Sunseeker and, bottom: Bombardier, Rolls Royce, Ninian Peckitt and Airbus.

GTMA Quarter page ad 29/9/11 10:16 Page 1

Supplier Partnership – Prime Machinery is presented by

0019.indd 1 26/9/12 10:33:38