A new, revitalized ResTech Plastic Molding Inc. is emerging, as the company recently completed a new ISO Class 7 clean room, added new machinery and developed a new training program to help its operators.
“We focus on growth and excellence, but the only people who can do it are the employees or the associates,” said George Danis, owner and CEO of the Hudson company.
“To get results you need to give them the tools, and the training program is one,” he said.
Danis said usually a book or paperwork is prepared to help with a project, but ResTech wanted to go further and installed a video system on machines that details what to look for and how to handle a job. The system is installed on 10 units and plans are in the works to build four more. The company also plans to add an audio component.
The program is a tightly controlled process in that various departments and the customer have to sign off before it is implemented. It is then shown on a screen in English, Spanish and Portuguese.
The training system contains many aspects. It shows what finished parts should look like and even how to pack them.
Quality assurance manager John Metcalf said he's compiled hundreds of books, but the problem is getting people to read them when they need them. The new system is getting a much more favorable response rate.
“We improved our quality 50-60 percent since we've installed it. It's really amazing,” Danis said.
ResTech Corp. was established in 1976 and had plants in Leominster and Clinton, Mass. It was acquired in 2010 by Danis and Plastic Molding Manufacturing Inc. All three plants have been consolidated in Hudson as ResTech Plastic Molding, which occupies 60,000 square feet of a 200,000-square-foot old mill building. The facility has plenty of room to expand if need be.
When the deal was made, Danis said, the companies had 90 employees. Now, the combined staff has grown to 125. The facility has been upgraded and includes a climate-controlled toolroom and tool-storage space.
ResTech designs and makes its own tooling on-site. It has a preventive maintenance program and guarantees the life cycle of all its tooling projects.
The Class 7 clean room has two JSW electric injection molding machines; four more are on order. Overall, ResTech has 30 machines, with clamping forces of 30-770 tons. The company has an aggressive machine replacement plan, targeting 10 new electric machines through 2013. It also intends to buy 10 machines in 2014.
ResTech operates in end markets including industrial, health-care, electronics, transportation, defense and security. It is also getting a boost with work coming back from China, gaining two projects that had been done overseas.
Danis said sales have been steadily rising about 15 percent a year over the last three years. He expects the same this year.
Employees have bonus programs and quarterly lunches as incentives and a way to keep them informed.
“We all need to work together and the community is also very important,” said Danis.
He added that a key project for the company is to fund and volunteer for a Thanksgiving Day turkey dinner for senior citizens.