mold-a-matic corporation r-s-009 rev. c 1 an iso 9001 / qs 9000 certified company

Mold-A-Matic CorporationR-S-009 Rev. C

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MAMCOPrecision Moldings

AN ISO 9001 / QS 9000 CERTIFIED COMPANY


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Molded Components.....Molded Components.....Your Source for Precision CustomYour Source for Precision Custom

Specialists in Insert MoldingAutomatic loading systems, reel to reel molding, standard shuttle and rotary molding machines.

Program and Design ExcellenceProgram Management focused on early product development.

FocusManaging total quality in all phases of our operation to achieve and exceed customer satisfaction and expectations.

Technological Systems in PlaceCad Design - Modem, Mold Flow Simulation, Molding Process Control, SPC, JIT and EDI, Bar Coding, Full Automation Systems


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Statement......Statement......MAMCO Vision/MissionMAMCO Vision/Mission

Continue to grow....as a World Class, Continue to grow....as a World Class, vertically integrated, precision custom vertically integrated, precision custom injection molder....by exceeding all injection molder....by exceeding all customer requirements through employee customer requirements through employee team involvement.team involvement.


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Incorporated in 1964, MAMCO (Mold-A-Matic Corporation) has grown to becomean industry leader in the development, design, and manufacturing of precisioncustom molded components and assemblies.

As a producer of engineered molded parts and assemblies, MAMCO utilizes all gradesof thermoplastics throughout their manufacturing process. MAMCO’s trained, motivatedand dedicated employees are working three shifts, five days per week, within a 30,000square foot facility with 32 molding presses ranging in size from 15 to 210 tons.

MAMCO’s 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-conductorindustries. With qualified engineering, quality and production professionals, MAMCOis able to embrace the concept of “Managing Total Quality” (MTQ) throughconcurrent engineering, continuous quality improvements and the guidance of our established ISO 9001 and QS 9000 standards.

Corporation.....Corporation.....Mold-A-MaticMold-A-Matic


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Binghamton

Oneonta

Cooperstown

Albany

MAMCO MAMCO is conveniently located in central New York betweenthe cities of Binghamton and Albany on Interstate 88 and 20 miles Southof Cooperstown, home of the Baseball Hall of Fame.

New York City

Syracuse


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Offers.....Offers.....MAMCOMAMCO

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 MAMCO’s ISO 9001 /QS 9000 certification.


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12512 MM USD

Annual Sales.....Annual Sales..... MAMCO Employees.....MAMCO Employees.....

Serving the following industries…..Serving the following industries…..

AerospaceAerospace

AutomotiveAutomotive

ComputerComputer

ConsumerConsumerProductsProducts

ElectronicsElectronics

TelecommunicationsTelecommunications

MilitaryMilitary

MedicalMedical


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Sales Distribution.....Sales Distribution.....MAMCO WorldwideMAMCO Worldwide

Electronics19%

Medical9%

Consumer Products

8%

Telecom 7%

Automotive45%

Computers6%Aerospace

2%

Military4%


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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 CENTURY MANUFACTURING

C & K COMPONENT 3M TELEDYNE CORPORATION

CTS BOURNS DALE ELECTRONICS

WARNER TECHNOLOGIES AMPHENOL BERG ELECTRONICS

HUGHES POWER PRODUCTS MOTOROLA CORNING, INC

TELEX CORPORATION ALLIANT TECHSYSTEMS VISHAY

IBM LOCKHEED MARTIN AMP

RAY-O-VAC GENERAL DYNAMICS SARGENT ART

EXERGEN INVACARE CORPORATION QA TECHNOLOGIES

TYCO ASTROCOM ELECTRONICS CHERRY AUTOMOTIVE

DELPHI / DELCO HARLEY DAVIDSON


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MAMCO FOREIGN CUSTOMERS

AB - ENGLAND AB - GERMANY HELLA

PHEH RUF VDO

SPECTROL VISHAY - ISRAELBOURNS

PHILIPS - HOLLAND


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AUTOMOTIVE CUSTOMERS

DOMESTICDELCO ELECTRONICS TRW

UTA DELPHI

ROCKWELL AUTOMOTIVE VISTEON AUTOMOTIVE

BREED TECHNOLOGIES DUNCAN ELECTRONICS

EATON CORPORATION 3M

AMP CTS

BOURNS DALE ELECTRONICS

ABROADAB - ENGLAND AB - GERMANY

HELLA PHEH

RUF VDO

SPECTROL BOURNS


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ELECTRONIC DOOR CONTROLS

MULTI-FUNCTION SWITCHES

INSTRUMENT CLUSTER COMPONENTS

(VISUAL AND NON-VISUAL) THROTTLE

POSITIONING SENSORS

TRANSMISSION TEMPERATURE

SENSORS

HEAD LAMP SWITCHES

AIR/FUEL SWITCHE

S

AIR BAG SENSORS

POWER SEAT AND HEAT SWITCHES

SEAT BELT COMPONENT

S

PRECISION COMPONENTS UTILIZED WITHIN:


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Secondary Operations:Automation SystemsPost Mold OperationsHot StampingPad Printing

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 PrototypesHigh Speed, Precision DiesMulti-Cavity MoldsAutomated Assembly Systems

Ship to Customer

Custom Inserts

Capabilities:Material: All Engineering Grades of ThermoplasticsSize: 1 Oz. to 4 Oz. 15 to 90 Ton 13 Oz. 210 Ton

Capabilities:Wire Brushes, Plastics,Screw Machine Parts, Castings, Varsities, Wire Forms, CapacitorsDecorative Appliqués

Capabilities: Material: Base to Precious and Bi-Metal

Semi or Fully Automation 100% Visual Inspection Vision Systems Attribute Checking Custom Testing Automated Packaging Tolerances: > .0005 In.

Forms of Assembly:

Custom To Meet Your Requirements

Capabilities:Reel to ReelTubeTrayStripsPiece Parts, Bulk

Process Capabilities....Process Capabilities....

Tooling

PrecisionStampings

Moldings

SecondaryOperations

CustomPackaging Assemblies

Engineered Solutions


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Statement.....Statement.....Quality PolicyQuality Policy

PolicyPolicyThe management and employees of Mold-A-Matic are committed to manufacturingproducts 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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Improvement Plan.....Improvement Plan.....Quality/ProcessQuality/Process

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.

MAMCO’s 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 9000specifications.


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Plan.....Plan.....Quality ImprovementQuality Improvement

MAMCO’s 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 FMEA’s 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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Indices......Indices......QualityQuality

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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Actions......Actions......CorrectiveCorrective

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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is Important in Insert Molding.....is Important in Insert Molding.....Concurrent EngineeringConcurrent Engineering

Part Designer Molder Insert Mfg.

Part Designer

Molder

Insert Molder

Time

TimeThe 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!MAMCO embraces early involvement through concurrent engineering!


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MoldFlow Part AdviserMoldFlow 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 2005Solidworks 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: [email protected]

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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Principles.....Principles.....Mold-A-MaticMold-A-Matic

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 FMEA’s 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.

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.


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Partnership.....Partnership.....MAMCO’s 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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Design and Determining FactorsDesign and Determining Factors..........Points of Consideration of a MoldPoints of Consideration of a Mold

1. Type of Mold

(a) Material to be Molded(b) Production(c) Size of Part(d) Dimensions(e) Inserts in Part(f) Shape of Part(g) Machine Availability and Size

2. Number of Cavities

(a) Production(b) Size of Part(c) Dimensions of Part(d) Inserts in Part(e) Machine availability and Size(f) Cost of Parts

3. Gate and Runner Size and Design

(a) Material to be Molded(b) Dimensions of Part(c) Shape of Part

4. Gate Location

(a) Dimensions of Part(b) Shape of Part(c) Appearance(d) Ease of Removal

5. Ease of Cavity Correction for Critical Part Dimensions

6. Location of Split Line

(a) Appearance(b) Ease of Cleaning(c) Dimensions of Part(d) Noted on Part Print

7. Ejecting Part from Cavity

(a) Ejector Pin Location(b) Possible Draft of Cavity(c) Part Distortion

8. Shrinkage of Material

(a) Past Experience(b) Material Manufacturer’s

Literature (Approx.)(c) Size of Part(d) Type of Mold(e) Uniformity of Part(f) Location of Gate or Sprue and Size of Gate(g) Insert in Part(h) Molding Techniques (Perform, Cure, Pressure, etc.)(i) Material Flow (Soft, Hard, etc.)(j) Design of Mold


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

9. Type of Cavity Construction

(a) Solid (Machined, Electrical Discharge)(b) Solid (Hobbed)(c) Laminated(d) Cast (Copper, Filled Epoxies,

etc.)(e) Plated Nickel and Copper(f) Combination of Above

10. Steel Selection, Heat Treat and Plating

(a) Production(b) Material to be Molded(c) Molding Pressures(d) Design Cavity Details

11. Side Draws

(a) Loose Block(b) Pull Pin(c) Air Hydraulic

12. Removable Solid Cavities

(a) Production(b) Ease of Loading Inserts(c) Cycle Time(d) Multiple Inserts(e) Repair of Cavities

13. Mold Base Selection

(a) Type of Mold(b) Type of Machine to be Used(c) Molding Pressures Needed(d) Cavity Layout(e) Type of Mold Heat

14. Type of Mold Heat (Oil, Steam, Water, Electric, Platen or Cooling

(a) Temperature Required for Molding Specified Material(b) Size of Mold Base(c) Type Available at Press(d) Accuracy of the Heat Needed


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Molding Definitions…..Molding Definitions…..Injection Molding:Injection Molding: Method of forming plastic to the desired shape byforcing the heat soft-end plastic into a relatively cool cavity (tool mold)under pressure

Thermoplastic Injection Molding:Thermoplastic Injection Molding: A process of thermoplasticpolymers in which melted plastic is injected into a mold cavity, where itcools and takes the shape of the cavity, bosses, screw threads, ribs, andother details can be integrated, which allows the molding operation tobe accomplished in one step. The finished part usually does not requireadditional work before assembling.

Insert:Insert: An integral part of a plastic molding consisting of metal or Other material that may be molded into position during the moldingProcess.


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Molding Definitions…..Molding Definitions…..

Cycle TimeThe total time required from shot to shot.

DraftA taper on the side wall or core pin of a cavity tofacilitate removal of the molded article from thecavity.

Ejector PinA pin used to remove the molded article from thecavity.

FlashThe portion of the charge which flows from or isextruded from the cavity during molding.

Flow MarkA visible mark resulting from the solidification of a pattern flow

ForceThe part of the mold that transmits the pressure of thepress to the top of the molding charge, for the materialinto the cavity.

GateA restriction in the runner at the point where the runnerEnters the cavity

PinThe part of the flash that is attached to the moldedArticle.


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Molding Definitions…..Molding Definitions…..

Air VentA groove in a mold which allows the trapped gasesin a cavity to escape.

CavityThe portion of the tool that contains the opening forproducing the desired shape and/or that area of the opening that forms the outer surface of the moldedarticle.

Cold Slug WellA space at the end of a runner or sprue to hold thecold slug and prevent it from entering the cavity.

Core PinA pin used to form a hold in the molded piece.

CoresThat portion of the mold that forms therequired inner surface of the molded article.

CullThe material remaining in the transfer potafter the mold is filled.

Cure of the Clamp TimeThe time the mold is closed to allow thecomplete chemical change of the material ofthe material to take place and/or allow thematerial to harden enough for ejection.

Core LinesThe holes in the mold base and/or cavity throughwhich passes a suitable liquid or steam tomaintain the proper mold temperature.


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What is Plastic?What is Plastic?Definition of Plastics (Society of Plastic Engineers): Definition of Plastics (Society of Plastic Engineers): “Any one of a large varied group of materialsConsisting wholly or in part of combinations of carbon with oxygen, hydrogen, nitrogen, and otherOrganic and inorganic elements which, while solid in the finished state, at some stage in its manufactureIs made liquid, and thus capable of being formed into various shapes, most usually through theApplication, either singly or together, of heat and pressure.”

In more technical terms, plastics have the following: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…..Material Properties…..Specific Gravity: The ratio of the weight of a given volume of material to that of an equal volume of water.

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.

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.

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.

Plasticity or Flow: The capability of a molding compound to fill a mold under prescribed pressure and temperature.

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.

Heat Resistance F: The temperature to which a part, under load, can continually operate without change in physical dimensions.

Deformation Under Load (Cold Flow): Dimensional change under a constant load at a given temperature.

Tensile Strength – PSI: The force required to break a given test specimen.

Compression Strength – PSI: The measure of compressive load to cause failure.

Flexural Strength – PSI: The maximum fibre stress sustained by standard test specimen, calculated from the bending load required to break.


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Material Properties…..Material Properties…..Modulus of Elasticity in Tension – PSI: The measurement of a force required to produce a given change in dimension.

Abrasion Resistance: The ability of a material to withstand mechanical action such as rubbing, scraping, or erosion. Expressed in volume lost.

Rockwell Hardness: Resistance to penetration from a standard load applied to a spherical ball for a standard length of time.

Arc Resistance – Seconds: The measure of the time required to produce a conductive path between two electrodes to the total current between them.

Insulation Resistance – MegaOhms – Volume and Surface Resistance: The ratio of the direct voltage applied to two electrodes to the total current between them

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

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.

Light Transmission – Percent: The measurement of the percentage of luminosity transmitted through a solid material.

Flammability: The length of time, in seconds, a material will burn for a prescribed distance, after removal from the source of flame.

mold-a-matic corporation r-s-009 rev. c 1 an iso 9001 / qs 9000 certified company

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