CORONA, CALIF. (Feb. 24, 11:15 a.m. EST) — AMA Plastics Inc. is crediting the decoupled molding process for operating improvements at the Corona company. CORONA, CALIF. (Feb. 24, 11:15 a.m. EST) — AMA Plastics Inc. is crediting the decoupled molding process for operating improvements at the Corona company.
Decoupled molding separates fill, pack and hold stages of injection molding with analysis from a resin perspective rather than that of molding machine settings. The process becomes an operating standard, reduces static-pressure variations and simplifies documentation.
The firm has invested about $20,000 for personal-computer-based production, process-control systems and cavity-pressure sensors, and $30,000 for training. AMA focuses on staying at the forefront of technology changes, according to President Mark Atchison.
Scrap rates improved to less than 1 percent from 5.5 percent, rework dropped to less than 0.25 percent from 2 percent and cycle efficiency jumped above standards to 105 percent from 93 percent, according to the company. The results compare 2003 and 2002, and the emphasis continues.
Ken Pravitz joined AMA as process engineering manager in July 2002. “They brought me in specifically because of decoupled molding,” he said.
Pravitz, who already had a background in the process, obtained Master Molder III certification from technology provider RJG Inc. of Traverse City, Mich., which allowed him to teach the process to other AMA employees.
AMA converted and requalified most existing jobs and set new job qualifications. AMA has 140 employees and adds 300-500 temporary workers as needed.
The firm was founded in 1971 and operates 70 presses with clamping forces of 35-720 tons. AMA molds precision parts for audio speakers, irrigation systems, water and fluid pumps, telecommunications call centers and noninvasive medical devices.