2013 The American Mold Builder - Winter

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The OfciaI PubIication of the
American MoId BuiIders Association
Winter 2013 Winter 2013
Lean Practices with EDM Graphite
Implementing Preventative Maintenance
Enforceable Mold Lien Procedures
AMBA Celebrofes 40 Yeors
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This is a special New Year Ior the AMBA. We
are celebrating our 40th anniversary and bringing
our annual convention back to where it all started:
CHICAGO. I have seen so many changes and
advancements in our industry in the last 28 years; it is
a real testament to the wisdom oI the AMBA Iounders
that they had the Ioresight to create an association that
is growing, thriving and adding value Ior its members
Iour decades later. The Iact that the AMBA has been
around since the Nixon administration and weathered
several economic downturns, including the Great
Recession, speaks volumes about the dedication and
hard work the leadership oI the AMBA has provided over the years. The
resilience oI our leaders and their ability to adapt to an ever-changing and
evolving mold building industry is incredible. Additionally, the AMBA has a
diverse membership that supplies nearly every manuIacturing industry Irom
electronics, toys and automotive to Iurniture, household products, packaging,
medical and many others. Each industry supplied has unique characteristics
and requirements. It is truly mind-boggling that our Iounders were able to
create this great association that is still relevant and growing today, as well as
diverse enough to be valuable to so many diIIerent mold builders serving so
many industries.
I think that one oI the key attributes our Iounders had was an ability to set
goals and measure success both in their businesses and Ior the AMBA.
With this mind-set, they could direct a course that was sustainable and
proftable. Truly, the ability to move Iorward on a successIul path requires
a clear understanding oI business strengths and weaknesses. Because the
AMBA exists to help our members improve and be more successIul, I am
proud to announce that the board oI directors has decided to continue the
benchmarking program that we started last year with Steve LeFever oI
Business Resource Services. The inIormation quantifed in the survey is
unique to our industry and is a priceless tool to measure business progress
and set goals Ior the Iuture. The Iact that we are providing this program Ior
a second consecutive year will give you the opportunity to track and trend
your progress, understand what makes your business proftable and be able
to clearly see which areas you have the best opportunity to improve so you
can Iocus your eIIorts. All you have to do to obtain this valuable data is to
participate in the confdential survey, the results oI which will be disclosed at
the AMBA Annual Convention (see page 37 Ior details).
The AMBA had a great convention in Grand Rapids last year, and we are
really excited about the program we have put together Ior you this April 24-
26 in Schaumburg, IL. I`m also very pleased that we are able to bring the
convention to the members by locating it in the Midwest, right in the heart oI
mold building country. I can`t wait, and I hope to see you there because some
oI the real value we get as members lies in the ability to network and help each
other by building relationships and talking through the challenges we Iace
every day (see page 18 Ior details).
Keep on building great American molds!
Todd Finley, Commercial Tool & Die
AMBA President
The American MoId BuiIder
Published by the
American MoId BuiIders Association
3601 Algonquin Rd., Suite 304
Rolling Meadows, L 60008
p 847.222.9402 f 847.222.9437
info@amba.org www.amba.org
Ofcers and Board of Directors
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Todd F|r|ey, Correrc|a| Too| & 0|e
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AMBA Team
Troy Nix, Executive Director
Kym Conis, Managing Director
Sue Daniels, Web/EMarketing/Member Services
Shannon Merrill, Business/Advertising Coordinator

Managing Editor: Kym Conis
Assistant Editor: Sue Daniels
Art Director: Cara Pederson
Advertising/Sales: Shannon Merrill
Circulation: Shannon Merrill
Opinions expressed in this publication may or may
not reect the views of the Association and do not
necessarily represent ofcial positions or policies of
the Association or its members.
6SHDN2XW
Todd Finley
AMBA President
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)RFXV
CelebrofinQ 40 Yeors of
Amerioon Molo MonufoofurinQ
I
n celebration oI the American Mold Builders Association`s
40
th
Anniversary, the AMBA would like to take this oppor-
tunity to provide a snapshot look at AMBA`s history the
events and milestones that have helped build our Iounda-
tion and shape our Iramework so that we may continue to
grow as a resource to our members. As AMBA Past President
Gerald Hobson (Hobson Mould Works, Inc.) said in honor oI
the AMBA`s 25
th
anniversary in 1998, '.we have the good
Iortune to learn Irom our history and prepare Ior our Iuture.
Back in the early 1970s, the American mold building indus-
try was rich with skilled craItsman who were excellent at
their trade. However, as talented as this group was, many
lacked the general business knowledge that would protect
their investment. According to Hobson, 'The Ioundation oI
the AMBA addressed this basic need and began the process
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oI providing moldmakers with not only a voice, but also a
powerIul tool in business management.
Today, while the mold building industry has seen many
changes since the AMBA`s inception in 1973, one key
Iactor has remained at the heart oI AMBA members
pride in American mold manuIacturing. On behalI oI the
AMBA Board oI Directors and the AMBA Management
Team and staII, the American Mold Builders Association
salutes its Iounding members who identifed the need and
took action to Iorm the AMBA. We also extend a very
special salute to our AMBA members Ior their support
over the last Iour decades, not only oI the Association but
even more noteworthy, Ior their support oI Iellow AMBA
mold builders - all Ior the greater good oI the American
mold building industry.
AMBA 1lmellne: 1913 - 2013
1973 Formation oI the American Mold Builders
Association - Chicago
1973 Art Dashut, Deluxe Die Mold, becomes frst
AMBA Chicago Chapter President
1976 Apprenticeship Training Program created
and launched
1978 First class oI 15 students graduate Irom AMBA`s
Apprenticeship Training Program
1978 Milwaukee Chapter is created
1978 AMBA hires frst Executive Director, Jeanette Bradley
1979 AMBA becomes an oIfcial National Association
1979 National Association Bylaws created and approved
1979 AMBA hosts its frst Annual Convention in
Lincolnshire, IL
1980 West Michigan Chapter is created
1983 Minnesota (Twin Cities) Chapter is created
1983 Minnesota Chapter creates frst brochure to
target students and spur interest in the industry
1985 Journeyman Certifcate created
1986 Southwestern Michigan Chapter created
1986 First issue oI the AMBA quarterly magazine -
'News & Views
1986 First membership brochure is created
1986 'Made in the USA mold plates created
1987 Southeastern Michigan Chapter created
1988 First issue oI the AMBA membership directory
is distributed
1989 AMBA hosts frst Annual Fall ConIerence
in Lansing, MI
1991 Central Wisconsin Chapter is created
1991 AMBA National Scholarship program is launched
1993 Indiana Chapter is created
7
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1994 First AMBA SoItware Survey is launched
1995 AMBA membership tops the 400 member mark
1996 AMBA launches website - www.amba.org
1997 Arizona Chapter is created
1997 First AMBA Business Forecast Survey is launched
1998 Scholarship program expands to distribute $10,000
1998 AMBA celebrates 25-year anniversary
1998 AMBA launches frst Wage & Benefts Survey
1999 Upstate New York Chapter is created
2000 Carolinas Chapter is created
2001 Mold Builder oI the Year Award program launched
2001 AMBA launches online enewsletter Weekly Beat
2002 Northern Ohio Chapter is created
2003 CaliIornia Chapter is created
2003 AMBA launches discount shipping program
with YRC Yellow Freight
2004 Central Wisconsin Chapter and Milwaukee
Chapter combined
2005 AMBA launches hugely successIul Traveling
High-Speed Machining seminar series
2005 Record attendance level achieved at AMBA
Annual Convention
2005 AMBA sponsors frst Mold Builders Pavilion
at PLASTEC West
2006 Re-launch bi-annual Mold Industry SoItware
Survey
2006 Creation and distribution oI new mold
manuIacturing career brochure
2007 Initiate mold-industry-specifc monthly webinars
2007 AMBA names new AMBA Executive Director,
Melissa MillhuII
2007 AMBA introduces OIfceMax member savings
program
2008 AMBA takes frst annual trip to Washington DC
to meet with Legislators
2008 AMBA launches updated website
2008 AMBA launches Partner Program
2009 Mold Buyers Corner introduced on www.amba.org
2009 Monthly OEM enewsletter launched
2009 Chapter oI Year Award Program launched
2010 Pennsylvania Chapter created
2011 AMBA names new management team:
Troy Nix and Kym Conis, First Resource
2011 AMBA launches MRO program with Grainger
and Legal Resource Program with Ice Miller
2011 AMBA launches highly successIul plant tour
workshop series
2011 AMBA Iorms alliance with Acrisure
2011 AMBA takes quarterly newsletter
(The American Mola Builaer) to magazine status
2011 AMBA launches new look and content Ior online
newsletter - EBeat
2012 AMBA brings Annual Convention back to
the Midwest: Grand Rapids
2012 AMBA hosts record-breaking Annual Convention
2012 AMBA launches frst successIul industry
benchmarking initiative
2012 AMBA launches discount program with
Expert Technical Training
2013 AMBA celebrates 40-year anniversary
2013 AMBA establishes Charter Membership in
honor oI frst eight companies to join the AMBA Q
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Most mold building executives understand
that the 4th quarter oI any year brings about
signifcant challenges as customers and
OEMs defne coming year budgets and oIten
become hesitant to make decisions at the
year`s end. This year, items multiplying the
impact oI the traditional year-end include
speculation about the plans oI the re-elected
administration and how the decision makers
will handle our country`s fscal responsibili-
ties to both its citizens and its debt holders.
However, the numbers reported by over 80 diIIerent frms
across the United States in AMBA`s most recent economic
survey indicate a more positive outlook on Iuture growth
than expected, and the outlook Ior the moldmaking indus-
try in general seems strong and steady.
Although some tooling shops are struggling, the general
population oI moldmakers in the US is seeing very good
market conditions. Currently, slightly over 8 out oI 10
oI the surveyed participants indicated that current busi-
ness conditions are either excellent or good (with the
overwhelming majority reporting good), and 17 percent
reported business being at least Iair (see fg. 1.0).
When considering business conditions, moldmak-
ing executives oIten look at their backlogs and 90-180
day sales pipelines to obtain the proverbial 'gut Ieel
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oI their own situation. However, adding to the positive
outlook is the Iact that profts also are being maintained.
From the last survey AMBA conducted in the Iall oI
2012, over 60 percent oI the survey participants indi-
cated that profts remained the same compared to today,
where over 70 percent now are reporting their profts as
remaining steady.
As can be seen in the historical chart (fg. 2.0), those indi-
cating profts are down also have improved Irom the last
survey period, moving Irom 20 percent to 16 percent oI
the participants reporting proft declines. However, there
does exist a cautionary fag about proftability that must
be noted. Beginning at the start oI 2012, a decreasing
trend line shows the number oI moldmaking executives
identiIying profts as being 'up has been on a consistent
decline Ior the last Iour quarters - nearly halI oI the posi-
tive responses received slightly over one year ago.
With this said, projections are even stronger with 93
percent oI the mold building population Iorecasting that the
business will increase substantially, moderately or remain
the same (see fgure 3.0). FortiIying the outlook is the Iact
that the Society oI the Plastics Industry (SPI) indicated in
mid-December that the value oI exported molds grew by 18
percent during the frst nine months oI 2012.
Compare your company`s current level oI business with
that oI three months prior in the Iollowing chart:
9
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info@wi-engraving.com
page 11 X
WORLD HEADQUARTERS
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Orion Twp, M 48359 U.S.A.
Tel: (586) 573-9450
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Quoting
Same
Up
Down

Shipments
Same
Up
Down
Backlog
Same
Up
Down
Profits
Same
Up
Down
1Q12
49%
27%
24%
1Q12
51%
35%
14%
1Q12
36%
37%
27%
1Q12
54%
32%
14%
2Q12
2Q12
51%
33%
16%
2Q12
55%
34%
11%
34%
41%
25%
2Q12
63%
25%
12%
3Q12
46%
34%
20%
3Q12
51%
28%
21%
3Q12
31%
33%
36%
3Q12
54%
22%
24%
4Q12
51%
26%
23%
4Q12
64%
21%
15%
4Q12
37%
34%
29%
4Q12
63%
17%
20%
1Q13
57%
20%
23%
1Q13
48%
32%
20%
1Q13
35%
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29%
1Q13
70%
14%
16%

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11
ZZZDPEDRUJ
Laurie Harbour, president oI Harbour Results, a
global manuIacturing consulting frm with strong
expertise in the moldmaking industry, recently
indicated that 'we have seen this demand continue
through the fnal quarter oI 2012. Based on the
backlog and demand seen with many moldmakers
in Harbour`s client base, Harbour has every expec-
tation this will continue well into 2013.

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Finally, 95 percent oI survey respon-
dents have maintained or increased their
workIorce levels while the 'work-week
hours have remained extremely consis-
tent over the last 18 months, running at
a median oI 50 hours. This is signifcant
because it continues to indicate a very
steady business climate Ior the majority
oI moldmakers (see fgure 4.0). Q
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WhoI Does 2013 ond
8eyond 8r/ng Mo/d 8u//ders?
By Laurie A. Harbour, President, Harbour Results, Inc.
For most mold builders, 2012 can be called a good year.
In Iact, many see the recession as a distant memory based
on booming volumes and Iuture Iorecasts. Tool build in
all industries is up as companies replenish their product
portIolio, and product complexity is at an all-time high,
thereby Iorcing more tool builds. All in all, companies are
returning to proftability. However, this proftability may
not be the best. and may come at a price.
Productivity is improved around the world, and compa-
nies are using their Iactory space more eIfciently than
ever. Based on recent mold builder assessments, many
are growing signifcantly; however, management oI that
growth has not in all cases been eIIectively controlled.
In some cases, companies are 'throwing labor at the
growth in a market where skilled labor is hard to fnd.
While profts are there Ior many, they are not as strong
as they could be iI the Iocus on continuous improvement
and planning was more robust.
That said, Ior most it still was a good year despite some oI
the concerns with the election, the fscal cliII, global pres-
sures and the struggle to fnd good talent. Going into 2013
and beyond, there are important things Ior companies to
consider and plan Ior as they look to improve their proft-
ability and long-term stability.
conomlc outlook
The fscal cliII brings a great deal oI uncertainty. Even
with a temporary delay or realization oI a long-term
resolution, there will be tax increases and spending
cuts. It`s not clear where these tax and/or spending cuts
will hit but rest assured, the unknown eIIect will bring
uncertainty in hiring oI talent, capital expenditures and
overall company spending. Tool shops are reluctant to
buy equipment and banks are unsure whether to support
mold builders long term.
Mold bulld cadence cllff
New mold build is up substantially across industries.
Based on the backlog and demands on many mold builders,
Harbour Results has every expectation this will continue
well into 2013. The cadence oI the automotive industry
and other industries that are revamping their product lines
will begin to pressure this demand, but not until late 2013.
Beyond 2015 is where the Iear lies. Although production
part volumes will remain high through 2020, the product
cadence oI many industries will level oII in 2015 and 2016.
All industries are rapidly launching new products in the
coming months and years in order to replace aging products
not changed during recession years. AIter these launches,
product cadence will balance back to pre-recession norms.
This means those that ramped up capacity will struggle to
fll it when the cadence drops. This is a major concern Ior
automotive, aerospace, heavy truck and appliance indus-
tries. Companies need to plan today Ior this cadence cliII.
Global lssues
From a global perspective, there is a great deal going on
throughout the world that puts pressure on North American
companies. The European crisis is ongoing and will take a
long time to reach stability. While Europe may not seem
critical Ior many, this market and its currency exert consid-
erable pressure on the global economy and have a major
impact on the US market. Additionally, many European
companies are looking to source more manuIacturing and
tool build in the US to support their own product that ends
up on US soil.
The Chinese government continues to give signifcant
incentives to those companies that manuIacture in China
and export to countries like the US. Tools kept in China
Ior internal consumption are taxed at higher rates than
those goods that are exported. This provides huge
incentive Ior China mold builders to market themselves
to US companies.
That said, the 2012/2013 Chinese ManuIacturing Outlook
by MAPI stated that aIter 10 years oI high-speed growth,
China`s auto industry is entering an adjustment period,
and the expansion pace will be moderate in the next two
years. Passenger vehicle production is being impacted
mainly by the gradual exit oI government stimulus poli-
cies and new regulations limiting issuances oI license
plates to reduce traIfc congestion in big cities. The
decline Ior commercial vehicles mostly is a result oI the
double-digit drop in investment, making truck production
more sensitive.
13
ZZZDPEDRUJ
The frst halI oI 2012 was very slow Ior growth in China.
Chinese policy makers will continue to control currency
to assure demand stays steady and growth continues, but
the traditional 25-percent growth rates may be a thing oI
the past. The wage rates in China will continue to increase
as it works to create its middle class. Expectation is that
wage rate diIIerences between the US and China will be
only 10 percent by 2016. This will give the US a greater
opportunity to retain manuIacturing and even export more
throughout the world. That said,
the next China is out there and
it`s only a matter oI time beIore
another competitive threat is there
to pressure US manuIacturers.
A new opportunity that many
mold builders are considering is
Mexico. Many years ago, custom-
ers were pushing plastics compa-
nies to locate or fnd a way to
support production in Mexico
because labor rates were low and
companies were locating there.
Then the China threat became overwhelming and most
large companies moved operations there due to Mexico`s
poor inIrastructure and lack oI talent (not to mention
China pricing).
The wage rates between Mexico and China are only pennies
apart and with Chinese wages creeping up, Mexico is better
positioned to support US manuIacturing. Additionally, the
talent gap is shrinking. In 2011, Mexico graduated over
90,000 engineers compared to
approximately 30,000 in the US.
The logistics and time zone advan-
tages, along with Iewer language
barrier issues, are making Mexico
an attractive sourcing option again.
In recent years, most all major
domestic, Asian and European
automotive manuIacturers have
made or are preparing to make
major investments in Mexico to
support consumption in Mexico,
South America and North America.
page 14 X
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This will Iorce suppliers to Mexico and the need Ior mold
support will be signifcant.
Many US- and Canadian-based tool shops have made
recent investments in Mexico with the plan to support
tool maintenance and determine Iuture builds as the
industry evolves.
1alent ool
Retaining, hiring and training people will continue to be
essential Ior the best and brightest companies. Retention
will be paramount Ior those companies that have strong
management and technical teams. The biggest gap Harbour
continues to see is in technical competency. In addition
to management, this lack oI competency also maniIests
in other areas such as operations, project management,
sales and quoting. Those resources that keep up with
ever-changing demands and advancements in technology
through continued learning and personal development will
maintain market position, proftability and overall fexibil-
ity Ior their company.
Finding new, young talent to enter the feld oI manuIactur-
ing is probably the number one challenge oI most compa-
nies today. Without fnding and training a new generation,
many industries - like moldmaking - may lose their busi-
ness to low-cost countries simply due to the lack oI inter-
ested talent. One approach taken by some oI the best US
manuIacturers to attract new talent is holding open house
events at their Iacilities to show the next generation the
changes in manuIacturing Irom the days oI their parents.
Although some have done this Ior years, a unique twist
on this approach has been to invite not just the young
adults but their parents as well. Most young adults are still
looking to their parents to support their decision making.
Once the parents see that manuIacturing is not what it used
to be, the prospect oI attracting young talent to manuIac-
turing plants is more likely.
bemand forecast and caaclty lannlng
Relative to other industries, mold builders are the
weakest at understanding Iuture demand and planning
their capacity. Most sales people will say it is impossible
to Iorecast sales, and operations managers tend to look at
capacity oI people or limitations on their equipment. It is
more challenging to plan capacity Ior a tool supplier in
comparison to a mass production environment. However,
the best organizations challenge their sales people to
develop relationships, understand the market in which
they operate, identiIy new models they want to support
W page 13
15
ZZZDPEDRUJ
in the Iuture and get a much better handle on potential
Iorecasts. Once that is understood, they work sometimes
daily with operations managers to manage and fll capac-
ity. It can be done but may require more creativity than
that oI past traditional tool suppliers.
value and rlce
With new programs and added complexity, tool cost is
being scrutinized more closely than ever beIore. OIten
times it is even diIfcult to sell value over price because
purchasing agents continue to be Iocused on cost reduc-
tion. Mold builders need to expand their thinking and
determine how to add value while reducing their price.
Their relationships with all levels oI their customers are
critical to illustrate that value; then they must deliver the
best quality product. The best and the brightest organi-
zations must get better and better at critical thinking to
assure they are exhausting every possible opportunity to
make themselves better. More than ever, quality is club
dues` and those Iorward-thinking organizations that
can bring something new to the table will get the gold.
The low-cost producer model without creative thinking
and problem solving will become a thing oI the past.
Me &cz
~~UL cc~v&~1c~
Operotionol/Finonciol 8enchmorking Doto
8est Froctices from ndustry Executives
Flont Tour Workshops
Feer-to-Feer Exchonge Forums
5oles ond Morketing 5trotegies
'HWDLOVRQSURJUDPPLQJUHJLVWUDWLRQDQGDFFRPPRGDWLRQVDWZZZDPEDRUJ
page 16 X
While other suppliers turn their
backs to supply other hot markets,
were stocking inventory, investing,
and servicing our customers 110%.
Its been that way for the past 100
years and will continue for the next
100 years. At ESS, we always focus
on our number one priority you.
Its what we do.
United States
Ellwood Specialty Steel
800-932-2188
esssales@elwd.com
Canada
Ellwood Specialty Metals
877-978-2772
esmsales@elwd.com Ellwood Specialty Steel - Ready and Reliable.
Were Focused on You.
W page 15
Creative thinking is the real secret to the overall perIor-
mance oI the best manuIacturers.
Mold builders have many challenges in Iront oI them. The
key is to not let the current volume and product complexity
blind them as to the Iuture beyond 2016. Things will slow
again but not to recession level. Those tool suppliers that do
not make business improvements may get business today
but aIter 2016 when things level oII, customers may go back
to their core mold builders as capacity normalizes. What are
mold builders doing today while things are good to ensure
their long-term success? How will business fex back down
iI needed? These questions are the keys to the Iuture. Q
Combining operational ana hnancial aavisory expertise
with inaustry analysis ana thought leaaership, Harbour
Results aelivers results that impact the bottom line. The
company speciali:es in manufacturing, proauction opera-
tions ana asset-intensive inaustries, as well as a number
of manufacturing processes incluaing stamping, tooling,
precision machining ana plastics. For more information,
visit www.harbourresults.com.
17
ZZZDPEDRUJ
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Thursday, April 25
8:30-10:00 om lgnite Sessions
10:00-10:30 om Exhibitor Networking Break
10:30-11:30 om Comparing FerIormance Leads
to lmproved FroItability
-ICHAEL"OHNING#REATIVE
"LOW-OLD4OOLING
11:30-1:00 pm Lunch and Flant Tour Breakouts
1:00-1:30 pm Depart Ior Flant Tours
1:30-3:00 pm Flant Tours (Arrnds will pic| on
rour whn rgisrring. visir omLo.org
lor droils.)
3:00-4:1S pm Return to Renaissance Ior Tour
Cross-Exchange
:30-7:30 pm Awards Reception
7:30-:30 pm Awards Banquet
Friday, April 2
8:00-:30 om Market or Die: 5 Strategies
to lmplement Now
*ON'OLDMAN"RAND,AUNCHER
:30-10:00 om Exhibitor Networking Break
10:00-11:30 om Functional Area Engagements
Ior StaII FroIessionals
11:30-11:4S om Convention Wrap
4ROY.IX-"
12:00 pm Convention Adjourns
Me &cz
~~UL cc~v&~1c~
"Fush rh Boundoris" or rh 2013 AMBA Convnrion, April 24-2, or rh Rnoissonc Horl ond
Convnrion Cnrr, SchoumLurg L. Losr yor's convnrion in Crond Ropids drw rcord orrndonc os
mold Luilding prolssionols gorhrd lrom ocross rh counrry ro shor Lsr procrics ond lorn woys
ro improv rh prolroLiliry ol rhir moldmo|ing oprorions. This yor's convnrion will provid oll rhor
ond mor. chollnging orrnds ro Fush rh Boundoris ond loo| or rhir mold Luilding oprorions
lrom lrsh nw ongls.
From pr-ro-pr xchong lorums, plonr rour wor|shops ond dynomic sols ond mor|ring srrorgis
ro rh lorsr indusrry doro ond mrrics lrom rh AMBA 2013 Bnchmor|ing nirioriv, orrnds will
lov nrgizd ond morivord ro implmnr chong.
For convnrion droils, including pricing, onlin rgisrrorion ond horl, visir www.omLo.org.
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Wednesday, April 24
7:00 om Rgisrrorion pns
8:30-:00 om Convention Kick-OII
4ROY.IX-"
:00-10:30 om Keynote Fresentation:
Building High-FerIormance Sales
and Management Culture
*ACK$ALY
10:30-11:00 om Exhibitor Networking Break
11:00-12:00 pm 2013 - Year oI the Economic
Experiment
$R#HRIS+UEHLRMADA
#ORPORATE)NTELLIGENCE
12:00-1:1S pm Lunch
1:30-2:30 pm Best-ln-Class Mold Building
Strategies: An lnside Look
,AURIE(ARBOUR(ARBOUR
2ESULTS)NC
2:30-4:00 pm Breakout Sessions
Smart Selling: Leverage
Growth with Systems & Frocesses
*ACK$ALY
Methods to SuccessIully lmprove
FroItability by Knowing Where You Stand
0ANELOF-OLD"UILDING%XECUTIVES
When OSHA Comes
Knocking, Will You Be Ready?
2ICK-ILLERAND3TEVE6ANDER(ILLCRISURE
:00-8:30 pm Welcome Reception
19
ZZZDPEDRUJ
Convention Sessions
Day One
Keynote - Bulldlng a Rlgh-
Performance 5ales and 5ales
Management Culture
*ACK$ALY
You con smll o culrur. Spnd
30 minurs or lss or o compony
ond you con dscriL rh culrur.
r moy L dillculr ro idnrily your
own culrur Lcous you hov
Lcom so much o porr ol ir.
Howvr, vry orgonizorion hos on, ond ir's virol
ro idnrily rh |y locrors in yours ond inrnrionolly
monog rhor culrur. Joc| Doly's |ynor sssion
hos Ln dsignd ro hlp compony lodrship
rcogniz rh imporronc ol o proocriv corporor
culrur ond irs Lorrom-lin llcrs on prlormonc,
whil providing innumroLl xompls ond idos
rhor con mo| on immdior, posiriv improvmnr
ro o compony's culrur.
2013 - ear of the conomlc
xerlment
$R#HRIS+UEHLRMADA
#ORPORATION)NTELLIGENCE
This is rh yor rhor immovoLl
oL|crs srorr ro ncounrr irr-
sisriLl lorcs ond ir is nor or oll
clor who will win in rhis rug-ol-
wor. Th dLr ond dlcir issu
srill looms Lur so dos rh nd ro lnd o woy ro
grow rh conomy. Th prioriris ol Congrss, rh
Frsidnr, rh Lusinss communiry ond rh consumr
or divrging mor rhon vr ond rhr is considr-
oLl dLor ovr whrhr rh lurur proLlms will L
wors rhon rh currnr ons. Forcosring ond rrnd-
ing rhis yor will L mor rhon o lirrl chollnging.
Best-ln-Class Mold Bulldlng
5trategles:
An lnslde Look
,AURIE(ARBOUR(ARBOUR
2ESULTS)NC
Louri HorLour, prsidnr ond
CE ol HorLour Rsulrs, nc.,
ond hr rom or xprrs in rool
monulocruring. HorLour Rsulrs
hos Ln in ovr 1S0 rool monulocrurrs oround rh
world in rh losr rwo yors conducring rhorough
rwo-doy Lusinss ossssmnrs covring vryrhing
lrom monulocruring ro lnonc ro sols ond mor|r-
ing. Sh will prsnr ro AMBA mmLrs Lnchmor|-
ing inlormorion lrom rhos rooling ossssmnrs,
olong wirh Lsr procrics sn oround rh world
or rh Lsr lociliris. Thr or mony mold Luild-
rs in rh US rhor hov mod signilconr chongs
in rhir mold Luilding procsss, schduling, sols
ond mor|ring, Lusinss plonning ond orhr oros.
HorLour will shor mony ol rhos Lsr procrics ond
mor imporronrly, sh will shor "how" ro implmnr
rhos srrorgis wirhin your lociliry. This sssion will
provid rol-lil xompls ond srrorgis lor impl-
mnrorion in your lociliris. Addirionolly, HorLour
will ro| qusrions lrom rh oudinc ro Lrrr
shor rh xprincs sh ond rh HorLour rom
hov sn during rhs ossssmnrs.
Breakout 5esslons
AMBA convnrion orrnds will hov opporruniris
ro ngog in smoll, rorgrd sssions. During rhs
discussions, indusrry xcurivs ond loding xprrs
will L on hond ro shor inlormorion ond doro whil
prolssionol mring locilirorors induc discussion,
cross rol| ond qusrion ond onswr priods.
5mart 5elllng: Leverage Growth wlth 5ystems
and Processes
*ACK$ALY
r's hos Lcom clor in rodoy's Lusinss climor
rhor |nowing "whor" ro do is nor nough, whor
is rolly ndd is rh "how" ro do. Th |y ro
growing on's Lusinss rsrs wirh on llcriv
sols rom lod Ly o clor vision. This coms
down ro xcurion - xcurion ol rh propr
sysrms ond procsss - rhroughour rh sols
rom, ro Lorh win nw cusromrs ond grow rh
ons you olrody hov. This sssion is hovy on
idnrilying rh rhings rhor nd ro L don - "rh
whor"- ond rhn grring morivord ro ocrivly
ngog in "rh how" ol purring rh procsss in
ploc in your compony. Bsr xcurion is ndd
in rodoy's mor|rploc. "Sysrms ond Frocsss"
or rh Losic rquirmnrs lor roLusr growrh ol
rh rop ond Lorrom lin.
page 20 X
Day Two
lgnlte 5esslons
-"-OLD"UILDING%XECUTIVES
Th horr ond soul ol rh onnuol convnrion
cnrrs oround popl hlping popl, hlping
och orhr ro Lcom rh Lsr mold Luildrs in rh
world, hlping och orhr solv common proLlms
wirhour rinvnring rh whl. NEW ro rhis yor's
vnr will L sssions dsignd ro Lring rhoughrs,
idos ond implmnroLl solurions dircrly ro you.
No nd ro go loo|ing lor nw ond croriv woys ol
doing Lusinss os rhs gnir Sssions will lorur
your indusrry prs opnly shoring whor rhy hov
ocruolly don ro improv rhir own Lusinsss.
Alrhough nor oll solurions moy dircrly lr, orrnd-
s or ncourogd ro rhin| ol rh mony lorms ol
rh solurions rhor could L odoprd ro rhir own
componis. Flos rmmLr, rhs indusrry xc-
urivs hov volunrrd ro shor som ol rhir own
improvmnrs ro hlp you, rhis ocriviry rinlorcs
rh ossociorion's principls ond volus!
gnir Sssions hov Ln dsignd ro L losr,
inlormoriv, lun ond locusd! Frsnrrs during
rh gnir Sssion will convy srrorgis ond
rocrics rhor hov invigorord rhir compony.
During rhis quic| hirring sssion, mulripl prsn-
rorions will L givn in shorr S-minur Lursrs.
And ro mphosiz ogoin, rhs or nor prolssionol
spo|rs, Lur rorhr indusrry prolssionols who or
shoring ro hlp you!
Comarlng Performance
Leads to lmroved
Protablllty
-ICHAEL"OHNING#REATIVE
"LOW-OLD4OOLING
Winning o roc is norly impos-
siLl il rh porriciponrs hov no
|nowldg ol rhir own posirion
ond no undrsronding ol rh
spd ol rhos oround rhm. r
is lor rhis vry roson rhor rh
Amricon Mold Buildrs Associorion hos sroLlishd
nwly documnrd Lnchmor|s rhor will noLl
compony lodrs ro comprhnd rhir own posirions
in rh mor|r ploc whil undrsronding rh "spd
ol prlormonc" ol rh indusrry os o whol. Drivd
lrom rh AMBA's lorsr 2013 indusrry srudy covring
Lorh lnonciol ond oprorionol mrrics ol rh mold-
mo|ing indusrry, rhis inlormoriv sssion will provid
W page 19
Methods to 5uccessfully lmrove Protablllty
by Knowlng Where ou 5tand
0ANELOF-"-OLD"UILDING%XECUTIVES
This sssion will locus on Lringing mor Lloc| ro
rh Lorrom lin ond will includ o ponl ol mold-
mo|ing xcurivs who will rvol how rhy us
AMBA's indusrry Lnchmor|s ro idnrily oros ol
opporruniry in rhir own componis. As porriciponrs
will quic|ly undrsrond lrom rhis opn discussion,
Lcoming lomilior wirh o compony's posirion whil
xomining spcilc prlormonc mosurmnrs is
only rh Lginning. To|ing ocrion ro clos gops
ond using Lsr-in-closs mrrics ro driv o compo-
ny's improvmnr ocriviris is rruly whr compony
xcurivs s corrlorion ro Lnchmor|ing ond
incrosing nr prolrs.
When 05RA Comes Knocklng, Wlll ou Be
Ready?
2ICK-ILLERAND
3TEVE6ANDER(ILLCRISURE
Alrr norly o dcod ol rlorivly lox nlorc-
mnr ond on mphosis on cooprorion, SHA,
undr Frsidnr Lomo, onnouncd inrnrions ro
incros inspcrions ond cirorions.
Thrlor, ir now is improriv your lociliry complis
wirh SHA rgulorions ond mploys musr |now
whor srps ro ro| il on inspcror shows up. Acrisur
hos hod succss conducring moc| SHA inspc-
rions or drills, whr on mploy (o solry dirc-
ror wirhin rh orgonizorion) or on oursid solry
consulronr poss os on inspcror ond voluors rh
lociliry's solry. Th cruciol inlormorion prsnrd
in rhis sssion could hlp prvnr hlry lns ond
prpor mploys lor on unxpcrd visir lrom
o rol inspcror. This sssion will covr rcnr
SHA dvlopmnrs ond how rhs rgulorions
could hov o ngoriv impocr on your Lusinss.
Addirionolly, rh sssion will covr rh lollowing:
How ro |now il you or rody lor your upcom-
ing SHA inspcrion
Whor rhings con you do now ro prpor?
Whor hoppns during on SHA inspcrion?
Whor rhings or you missing in prporing lor on
SHA inspcrion?
Disgrunrld mploy comploins ro SHA,
SHA is or rh door, now whor?
21
ZZZDPEDRUJ
compororiv prlormonc doro rhor will grorly ossisr
lodrship roms in idnrilying oros ol opporruniry ro
improv prolroLiliry in rhir own Lusinsss. Frsnrd
Ly indusrry vrron ond CFA Michol Bohning ol
Croriv Blow Mold Tooling, rhis highly onricipord
oddrss will signilconrly impocr orrnds.
Plant 1our Workshos
visir AMBA.org lor droils.
Day Three
Market or ble: Flve
5trategles to lmlement Now
*ON'OLDMAN"RAND,AUNCHER
n rodoy's hypr-compririv
monulocruring mor|rploc,
"m-roo" mor|ring |usr do-
sn'r cur ir. Th compririon is
Lrorhing down your nc|, ond
rh rhror ol your cusromrs
moving rhir occounrs ro Chino
is vry rol. You con'r ollord ro sir srill. n rhis nviron-
mnr, ir's "mor|r or di."
Hr's rh good nws: or rhis yor's AMBA convn-
rion, xprr Jon Coldmon will pull Loc| rh curroin
on powrlul, osy-ro-implmnr promorionol srror-
gis rhor gr rh |oL don. Wirh rh righr sols
mssog, you con orrrocr nw occounrs ond rroin
your currnr cusromrs. Join rhis nrrroining, inlor-
morion-poc|d sssion ond discovr lv y-opn-
ing rocrics ro opply NW:
Th worsr misro| mosr monulocrurrs mo|
ond how ro ovoid ir
Frovn srrorgis lor roching your Lsr
prospcrs
How ro go lrom "|usr onorhr vndor" ro
"rh rrusrd xprrs"
Th singl mosr powrlul word ro us in your
communicorions (nor "lr" or "you")
Th Lsr woy ro orrrocr nw occounrs using
"irrsisriLl Loir"
Functlonal Area ngagements for 5taff
Professlonals
Crowing pr-ro-pr nrwor|s ond hoving rh
opporruniry ro mr orhr individuols in similor
rols ond rsponsiLiliris or primory componnrs ol
rh 2013 Annuol Convnrion. During rhis ngog-
mnr sssion, prolssionols will xchong idos on
vorious ropics rlord ro rhir spcilc group. Sols
ond Mor|ring, Humon Rsourcs, Finonc (T & ERF
includd), prorions ond Frsidnrs/wnrs/Snior
Lodrship prolssionols will hov rh chonc ro
inrrocr wirh rhir prs on ropics rhor or uniqu ro
rhir |oL luncrions. Drivn Ly posr orrnd ldLoc|,
rhs locusd sssions hov Ln highly rqusrd
ond or xpcrd Ly convnrion orgonizrs ro L
on ol rh Liggsr hirs ol rhis yor's vnr. Ths
ngogmnr sssions or o prlcr woy lor prols-
sionols ro lnd nw idos, xpond rhir prolssionol
nrwor|s ond xplor nw mrhods ol improvmnr:
* Finonciol, ERF Sysrms ond T Frolssionols
* Humon Rsourcs Rlord ssus
* prorionol ond Frocssing Frolssionols
* Sols ond Mor|ring Frolssionols
* Exclusiv: Frsidnr ond wnr Lodrs
Rotel lnformatlon
Discovr modrn sophisricorion lrom o horl in
SchoumLurg loruring conrmporory dsign rhor is
xprssiv, yr luncrionol or rh Rnoissonc Scho-
umLurg Convnrion Cnrr Horl. Dsignd Ly rh
rnownd John Forrmon & Associors, SchoumLurg
horl occommodorions Loosr spocious, yr modrn
rooms ond suirs wirh ovrsizd Lorhrooms ond o
mdio conncriviry cnrr. ndulg your snss or rh
oword-winning Som & Horry's or rlox wirh lrinds
ond co-wor|rs in rh srylish CluL Loung. Spciol
AMBA ror is $13/nighr ond includs complimn-
rory por|ing, lirnss cnrr ond in-room inrrnr. For
rsrvorions, coll 800-48-3S71 or lor onlin rsrvo-
rions, visir www.omLo.org ond lollow rh convnrion
lin| ro horl rsrvorions. Q
INLO
Incrnduco LSR SorIo

SIngIo NnzzIo tnr LnId Spruo
AppIIcacInn
INCOE
Corporation, Troy,
MI, has developed a new
CSR replacement single
nozzle specifcally designed
Ior cold sprue applications.
The CSR is a smart choice Ior
replacing worn or outdated
cold sprue nozzles in exist-
ing injection molds with 1
max bores. Replaceable end
caps are supplied with extra
stock, providing the fexibili-
ty Ior machining to any exact
dimension as required to ft
each application. The proven
integrated heater design, used on the DF Gold series oI hot
runner systems, incorporates two separate heating circuits
to provide uninterrupted production and reliability. In the
event oI a single heater circuit Iailure, the second heater
automatically provides continuous heating. For superior
thermal perIormance, the heating element is profled along
the nozzle body to apply heat exactly where needed Ior
optimal thermal control and repeatable material process-
ing. The new INCOE
CSR series oI single nozzles is

available in fve standard lengths and recommended Ior
small- to medium-sized molding applications oI commod-
ity-grade resin parts only. For more inIormation, visit
www.incoe.com.
FANLL DB1 RnbnDrIII VML SorIo
trnm Mochnd MachIno TnnI
Methods Machine Tools, Sudbury, MA, has introduced the
FANUC D21 RoboDrill vertical machining centers, which
include new state-oI-the-art control. The innovative FANUC
31iB control Ieatures extremely Iast, high-speed process-
ing, oIIers streamlined electronics to reduce the number
oI components and provides an ergonomic display. The
control also provides eIfcient troubleshooting and main-
tenance capabilities, allowing users to analyze systems on
the RoboDrills and receive notifcations iI any oI the drives
or electronics requires adjustment. The automotive-duty-
rated, versatile and reliable FANUC D21 RoboDrill VMCs
are available in three models including the D21-S (small),
D21-M (medium) and D21-L (large) sizes. The RoboDrills
oIIer a 14-tool or 21-tool tool changer, torque to 56 It-lbs,
rigid tapping to 5,000 RPM (8,000 RPM optional), accel-
erations (in X, Y, and Z axes) to 1.5 G, rapid traverses to
2,125 IPM, Ieed rates to 1181 IPM (2362 IPM optional),
high-speed reverse tapping, thread milling, 1,000 programs
that can be registered and 54 work oIIsets. Spindle RPMs
range Irom 10,000 to 24,000 with the option to utilize tool
changeable air spindles oI up to 90,000 RPMs. For more
inIormation, visit www.methodsmachine.com.
Now MIIIIng TnnI HnIdor tnr Hoawg-
Ducg LuccIng
The new SINO-R Irom
SCHUNK, Morrisville, NC, is
a maintenance-Iree tool holder,
especially well suited Ior rough
milling. The universal tool
holder is based on an expansion
technology system with a solid
body and a pressure medium,
quickly clamping the cutting
tool by using a simple actuation
wrench. This simple operation
saves unproductive machine
down-time. The excellent inter-
action oI high radial rigidity and
exceptional dampening charac-
teristics are special Ieatures that
increase the smooth running oI
the tool. The result is a high
tool liIe and increased mate-
rial removal rates. An additional plus Ior the user is the
tool holder`s fexibility, thanks to the use oI intermedi-
ate sleeves. Nearly all common tool shank diameters
can be clamped. SINO-R holds the tool securely, with a
maximum torque transmission (850 Nm (627 Ft-lb), at
a clamping diameter oI 32mm (1.25). It is precision-
balanced standard to G 6.3 at 15,000 rpm. For more
inIormation, visit www.schunk.com.
3URGXFW
23
ZZZDPEDRUJ
page 24 X
DM Launcho LIno nt XK Kogod
joccnr PIn
DME Company, Madison Heights, MI, has
introduced a line oI EXK keyed ejector pins
in response to customer demand Ior a wider
range oI sizes. The overall DME keyed pins
line, including its existing THXK keyed pins
oIIering, now is doubled in size and has lengths
up to 25 to better meet the needs oI molders
using thick plates. Keyed pins are designed to
prevent rotation during the injection molding
process. Precision DME machining creates
the 'key on the head oI the pin to hold the
pin in place, eliminating damage to the parts
being molded or even to the mold base itselI.
Made Irom superior quality, thermal shock-
resistant hotwork steel, DME keyed pins are
ideal Ior use in high-temperature applications.
On the Rockwell hardness scale, the core oI
the pins measures a hardness oI 40-45HRC.
Outside diameter is nitrided to 65-74 HRC.
These high scores show that DME keyed
ejector pins withstand the stress presented by
industrial use. Pins now are available in 1/8
to 1 diameters and 6 to 25 lengths in both
the EXK and THXK keyed pins lines. For
more inIormation, visit www.dme.net.
IncrnducIng HLL
,
MIcrn SorIo
DoburrIng TnnI
HEULE, Cincinnati, OH,
introduces the new MICRO
series carbide tool Ior all-
purpose deburring oI through
holes 2mm-4.1mm (.079"-
.161"), Iront and back, in
a single pass. HEULE`s
MICRO COFA deburring
tool is the answer Ior tod-
ay`s manuIacturers requir-
ing more simple and fexible
solutions without sacrifcing
quality or tool liIe. MICRO
COFA is a very simple
tool Ior deburring through
holes on even or uneven
parts Irom the top and bot-
tom without reversing the spindle, dwelling or indexing
the part. The MICRO COFA tool oIIers a simple-to-use,
high-quality deburring tool with carbide inserts coated
with TiAI to meet today`s manuIacturing needs. For more
inIormation, visit www.heuletool.com.
GF AgIoLharmIIIo Incrnduco Now
HSM BDDL LP MIIIIng MachIno
GF AgieCharmilles, Lincolnshire, IL, will announce
the new high-tech, high-speed MIKRON HSM 200U
LP milling machine at the 2013 Medical Design and
ManuIacturing (MD&M) West Show in booth 4167.
Available in 3- and 5-axis versions, the MIKRON HSM
200U LP (linear perIormance) brings speed, eIfciency
and precision to the machining oI small, highly complex
components, such as medical implants, electrodes
and watch components. With a compact Iootprint, the
machine easily fts into most Iacilities, which is key
to foor space with extreme limitations. The MIKRON
HSM 200U LP can produce workpieces via true 5-axis
simultaneous high-speed machining. Linear motor tech-
nology in the main machine axes and optimized direct-
drive motors Ior the B and C axes result in high precision
and superior part surIace fnishes as fne as Ra 0.05 m.
Furthermore, the machine`s powerIul 50,000-rpm,
11.4-hp Step-Tec spindle also assists in providing excel-
lent surIace fnish and part detail. For more inIormation,
visit www.gIac.com/us.
SocnI
,
WnrRPLAN ncorprIo
Sgcom AchIowo SAP-LorcItIcacInn
Sescoi International SAS, Macon, France, announced
that version 4 oI its WorkPLAN Enterprise system Ior
project-based manuIacturing has achieved SAP-certi-
fed integration with SAP
applications. Through this

integration, data can be exchanged between the Work-
PLAN Enterprise system and the SAP ERP application.
Companies then will be able to beneft Irom the
specialized manuIacturing and project manage-
ment tools built into WorkPLAN Enterprise, geared
towards maximizing productivity and eIfciency.
The SAP Integration and Certifcation Center (SAP
ICC) has certifed that WorkPLAN Enterprise V4 inte-
grates with SAP ERP 6.0 via the 'plant data collection
shop-foor control (PP-PDC 4.6) integration scenario.
For more inIormation, visit www.sescoi.com.
highly eIfcient material removal with minimal vibration
and wear. Emuge`s Top Cut end mills are made oI micro-
grain carbide, Ieaturing proprietary relieI ground cutting
edges, making Top Cut uniquely capable oI perIorming
roughing as well as fnishing cutting operations, greatly
adding to the versatility oI these tools. For more inIorma-
tion, visit www.emuge.com.
nd MIII HnIdor Sgcom
Nexus Cutting Tools Irom Techniks, Indianapolis, IN, has
introduced a patented ShrinkLOC System, which is built
around the patented PowerLOC indexable end mill with a
square shank end. This end mill locks into the square ftting
in a Techniks ShrinkLOC tool holder. Nexus' ShrinkLOC
holders eliminate tool slippage a major concern when
manuIacturing high-value parts. The tool shank and the tool
holder are locked tougher, making it impossible Ior the tool
to spin, even under the heaviest loads. For more inIorma-
tion, visit www.techniksusa.com. Q
Corroplast FM is the new stainless steel mold base material available
exclusively from SCHMOLZ+BICKENBACH. The team of metallurgical engineers
from Deutsche Edelstahlwerke GmbH specically developed this grade for the
plastics tooling industry.
Corroplast FM offers the benets of an improved microstructure, superior
machinability and excellent corrosion resistance compared to other free
machining stainless grades.
Corroplast FM is ideally suited for mold bases, manifold plates, hot halves
and other plastics tooling associated with processing corrosive resins
(PVC) or used in corrosive manufacturing environments.
For more information about Corroplast FM, please visit our
website or contact us at (800) 323-1233 ext. 2295.
USA www.schmolz-bickenbach.us (800j 323-1233 - Canada www.schmolz-bickenbach.ca (800j 268-4977
mugo Incrnduco HIgh-
Portnrmanco nd MIII
Emuge Corp., West Boylston,
MA, has introduced Top
Cut
, a new series oI high-

perIormance carbide end
mills. OIIered in a wide
range oI metric and inch
sizes, styles and geom-
etries, Top Cut provides
Ior maximum versatility
in milling a broad array oI
materials, including hard
steel up to 55 HRC. Ideal
Ior mold and die, as well
as general milling applica-
tions, Emuge`s Top Cut end mills Ieature a new and unique
variable helix fute technology and a newly developed
variant oI the high heat-resistant TiAlN coating. These
Ieatures, in addition to internal coolant capabilities, enable
W page 23
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25
ZZZDPEDRUJ
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High-precision milling
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By Barry J. McKenna, President, McKenna Service Company
Machinery requires routine maintenance. Period. Those
involved in mold manuIacturing are aware oI the value oI
maintaining their machinery and tools as in most cases,
substantial amounts oI time and money have been spent
to acquire the proper mold manuIacturing equipment.
Regular preventive maintenance (PM) can help to protect
and prolong equipment liIe and perIormance, which results
in a Iar greater investment return Ior each machine.
Most companies have the best intention oI implementing a
preventive maintenance program but rarely do. OIten this
is simply because on a day-to-day basis, production output
tends to trump maintenance. Many mold manuIacturing
Iacilities commonly place more emphasis on production
rather than machine maintenance because they must stay
Iocused on production output to maintain company proft-
ability. This strategy works just fne until that day comes
along when a machine breaks down. As everyone knows,
it never happens at a convenient time and most oIten it`s
at the most inopportune time, i.e., the middle oI an impor-
tant production run on a weekend. As an expert in the
machinery service business, I am constantly tasked with
responding to emergency customer equipment break-
downs that oIten could have been prevented by simple
preventive maintenance.
A PM program will enable the production planner to make
inIormed decisions about production schedules based on
pre-planned maintenance outages. It can substantially
minimize unexpected machinery downtime by allowing
managers to actually schedule the downtime instead oI the
machine scheduling it Ior them.
lmlementlng a PM rogram
First, preventative maintenance program implementation
takes inIormation gathering and planning. Begin by assem-
bling pertinent inIormation on every piece oI equipment in
the building. It must be cataloged, organized, reviewed and
then stored in an accessible location. Develop a database
that includes all oI the maintenance and service records Ior
every piece oI equipment. This can help identiIy mainte-
nance issues by individual machine. Based on this database,
timetables can usually be easily identifed on perishable
components, which can then be used to pinpoint specifc
weaknesses associated with a component or a machine.
This inIormation can enable inIormed purchasing deci-
sions regarding the projected maintenance needs.
Economic conditions indicate that most companies are
not quite back to Iull throttle, so now is an ideal time to
institute a preventative maintenance program and bring
equipment back into good working order. One question is
whether an 'annual or 'semi-annual preventive mainte-
nance program should be put in place. To determine the
need, Iollow a common sense rule. Typically a year oI
machine liIe is based on a single shiIt operation Ior one
year. II there are two shiIts operating, it is equivalent to
two-year wear on the machine in one calendar year. II your
company has more than one shiIt operating per day, then
consider a semi-annual plan.
A PM program primarily begins with a detailed inspection
and cleaning oI each machine. Some examples oI places to
begin include the Iollowing:
Pull back way covers once a year and clean out the chips.
Chip build-up can destroy ways, way wipers, linear
guides and ball screws.
For those who use water-soluble coolants, be aware that
these coolants can build up on the machine surIaces
over time (they are designed as rust preventives). II the
machines are not cleaned periodically, limit switches
will begin to stick and other Iailures will occur, such
as the inability to reIerence axes, tool changer Iailure,
etc. Also, do not use solvents to remove the coolant that
has built up on the equipment; instead, use hot water.
Remember it is water-soluble.
Clean and inspect the Ians in the electrical cabinets. This
can keep electronic component temperatures cool and
will go a long way in preventing those expensive elec-
tronics Irom Iailing.
Replace hydraulic oil and flters in machines once a year as
it will help lower oil temperature and keep hydraulic lines
Irom leaking or blowing out. Inspect, repair or replace
hydraulic pumps and test their perIormance, pressure and
fow. Replace leaking or damaged hydraulic hoses.
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27
ZZZDPEDRUJ
HolJlow Anolysis Fxperts
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page 28 X
VeriIy that the proper amount oI lube is getting to the
spindle, ways, ball screws and lead screws to prevent
costly repair and rebuilds. Inspect and replace worn ball
screws and lead screws.
Discuss the machine and its operation with the person
who runs it on a daily basis. Educate employees and get
them involved in the process. Alert machine operators
oIten can point out problems to maintenance person-
nel long beIore a sudden stoppage happens. Have them
cycle the equipment and listen Ior any odd noises such as
bad bearings or worn belts.
Many manuIacturers have implemented certifcation
programs Ior their equipment to satisIy internal, as well
as external traceability requirements, such as ISO and
QS certifcation and compliance.
BeIore checking the positioning and repeatability on any
machine, frst check that the equipment is leveled properly.
Any twist in the base oI a machine (as caused by settling
over time) can cause erratic positioning readings. Check
and maintain the proper alignment oI all axes. VeriIy the
linear positioning and repeatability. Set the compensation
(i.e., pitch error comp) and veriIy with a laser interIer-
ometer system. Machine calibration services are avail-
able and are sometimes required to veriIy perIormance.
Prepare Ior planned maintenance rather than having to
react to a sudden non-compliance condition. Calibrating
machines with precision laser measuring equipment
will provide peace oI mind that the parts produced on
the machine will meet the tolerances customers demand.
Once the positioning has been verifed, maintain a
calibration library on all equipment and then plan to
re-calibrate annually. A machine's dynamic/interpolation
perIormance can be inspected using a ball bar. The ball
bar tool is the optimum method Ior inspecting or veri-
Iying the machine tool`s Iunction and dynamic perIor-
mance during operation.
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Every company needs electric power to Iunction. However,
manuIacturing requires and consumes larger amounts oI
power to operate the machinery within the Iacility.
Electric power supplied by power companies has a toler-
ance. In some cases, the voltage supplied may fuctuate
due to seasonal overloads, weather, etc. A line spike or
sag will cause other issues and cost consequences Ior the
end user.
II there have been excessive electrical-related mainte-
nance issues and component Iailures throughout the Iacil-
ity, it may be time to install power conditioning devices.
Line spike arrestors and/or buck/boost transIormers may
be needed to stabilize the power situation.
Review the repair and maintenance records. Remember
that ANY power variance will have an eIIect on anything
electrical in the building.
II there are ongoing issues, request that the power
company install a 'chart recorder on the incoming lines
Ior a week or so. II the power problem seems to occur
during certain seasons, have the recorder placed on the
lines during that time.
Review the recorder fndings with your electrician or
contractor as well as the power company.
Sometimes the problem is caused by the power company
due to bad switches or transIormers. An excessive power
fuctuation issue might even result in a rebate or some
other type oI corrective action.
The bottom line is that the cause oI the problem will
be resolved.
Many equipment downtime hours can be avoided by
early detection oI problems. A routine inspection helps
to expose potential issues beIore they become critical.
The beneft is both in extended production time and
avoidance oI premature component Iailures.
Malntalnlng the PM rogram
Monitor all maintenance activity with soItware technol-
ogy. SoItware will enable maintenance managers to quickly
and easily schedule and review recurring maintenance
tasks while reducing the time needed to administer service
requests. Use it to automatically generate work orders when
preventive maintenance is due. Use email and text messaging
to distribute work orders to your maintenance staII, as well
as to preIerred service vendors and suppliers. Documenting
these activities makes it easier to analyze trends and spot
recurrent problems.
There are some cases where a PM program will be oI little
value. This occurs when it`s implemented on equipment
that has been severely neglected and is in poor condition.
Addressing and correcting known problems can, over time,
restore the machinery to its optimum operating condition.
Preventive maintenance is an idea being adopted by manu-
Iacturers around the world and, plainly put, preventive
maintenance saves money! Q
W page 27
The author can be reachea by email at
barrymckennaservice.com, or for more information on
the company, visit www.mckennaservice.com.
29
ZZZDPEDRUJ
by UBM Canon
ubmcanonevents.com
Register today at:
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Leave your ofce behind and expand your skill set at PLASTEC West this February. Increase your knowledge
and your network by engaging with like-minded peers and industry thought leaders. Meet face-to-face
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February 1214, 2013
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Industry Peers Thought Leaders Ideas and Inspiration New Technologies
2
3
9
4
4
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1
3
Figure 1
Graphite oIten is an overlooked stepchild when assessing
EDM eIfciency. The sourcing oI graphite oIten Iocuses
only on the cost per cubic inch rather than the total value
delivered. Since it is a purchased commodity, little time is
spent considering the true costs oI each piece purchased
beIore it is used in the EDM process.
llmlnate waste
For most users oI EDM graphite, the principles oI lean
manuIacturing are well entrenched within company
management, supervision and workers. An important prin-
ciple oI 'lean is to eliminate waste. Waste can be defned
as any human activity that absorbs resources but creates
minimal or no value. Waste within a Iacility that uses EDM
can be present in many Iorms.
Many companies purchase large pieces oI graphite to
minimize costs. However, aIter the desired pieces are cut,
the smaller remaining pieces oIten fll shelves as unused
inventory and wasted graphite. Another common prac-
tice is using a grade oI graphite 'because it works. EDM
machine controls have advanced considerably during the
past years so grades currently used may not be the most
economical. Finally, the graphite holding system should
allow easy interchangeability between machines without
excessive indicating Ior location and squareness. Time
is precious and now economical EDM fxturing is avail-
able that will accommodate precise registry Ior electrodes
between machines.
Lean thinking can be Iar reaching but oIten is Iocused
only within the walls oI the mold or die manuIactur-
er. Companies that maximize the lean thought process
embrace the knowledge and experience oI their suppli-
ers, including graphite suppliers, to achieve greater value
Irom their purchases. This process oIten requires the buyer
to discuss value-added capabilities, blank estimating,
procurement times and methods to ensure on-time deliver-
ies. It is in the interest oI both parties to Iocus on removing
the 'physical walls to achieve an 'out-oI-the-box-ready
graphite blank Ior Iorm milling and EDM.
Many mold builders, as well as tool and die shops that
use EDM, have close relationships with their graphite
supplier(s). One example is the online Graphimator
soIt-
ware by Ohio Carbon Blank that was developed with input
Irom EDM users seeking to streamline their estimating or
*=GA6KQN"!*$N=LDEPA0QLLHU=)A=J-N=?PE?A
By Dale McCartney, General Manager, Ohio Carbon Blank
purchasing oI graphite blanks that are ready Ior CNC Iorm
milling. The soItware`s drop-down menu Iormats, easy-to-
use fll-in boxes and order confrmations ensure accuracy
each and every time an order is placed. Additionally, this
new tool also allows users to maximize the value oI their
rectangular or round blanks through pricing comparisons
Ior materials and the choice oI saw-cut, semi-precision or
precision-ground products. The soItware also eliminates
wasted phone time by allowing users to seek inIormation
and pricing on their time.
llmlnate more waste
Graphite blanks typically are ordered to the size oI the cavity
that is to be burned, oIten within .0001 oI an inch. However,
upon receipt oI a graphite blank, many customers must mill
the opposite end oI the blank to accommodate a specifc
graphite holder size common to their CNC mill and EDM.
This is particularly true when tool changers or robotics are
used as part oI EDM operations. Customers noted that to
achieve an out-oI-the-box-ready product, milling Ior the
graphite holder by the buyer must be eliminated. Although
necessary, milling Ior the graphite holder size does not add
value to the blank. Recognizing this Iact led to discussion
and question: 'Is there another way to avoid the milling
operation?
The solution was the development oI a two-piece bonded
graphite blank. This type oI blank would achieve the request-
ed out-oI-the-box-ready product and optimize the fexibility
oI both size and material combinations (see Figure 1).
7HFKQRORJ\
31
ZZZDPEDRUJ
The bonded blank exhibits high bond strength, excellent
conductivity and signifcant material savings Ior medium-
and high-density materials. This product also shortens
the overall graphite procurement time by eliminating
the customer`s in-house milling process Ior its graphite
holding requirements.
Bonded blanks were designed to eliminate the purchase oI
excess graphite (material waste) and remove milling oI the
blank by the purchaser (labor/machine waste) Ior mount-
ing in the work holders. In many applications, this bonded
product achieves signifcant savings by eliminating milling
time by the purchaser (see Figure 2). The signifcant savings
is achieved by bonding low-density, low-cost graphite used
Ior holding (the 'backer) with a higher-density material,
which contacts the work piece (the 'burner) during the
EDM process. When the new bonded blank is used Ior the
last time, throw away costs also are minimized, thus reduc-
ing more waste.
Currently, Erowa and 3R oIIer graphite holders in limited
metric sizes. Additional holders designed specifcally Ior the
bonded product in sizes ranging Irom .5 to 2 square in /
increments have been designed by Ohio Carbon Blank. All
holders can be ordered with either the Erowa or 3R hole
patterns. Quick-change holders are the key to economically
reducing setup time and attaining precise registry between
machines that are equipped with the quick change tooling.
Most mold or die manuIacturers that use EDM have
standardized their electrode milling and EDM using
the Erowa, 3R or other graphite holder systems.
These holding systems require a series oI attachment and
alignment holes.
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page 32 X
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The bonded product can be provided with the Erowa or
3R hole (50 or 100mm) patterns upon request. A Iuture
release oI the purchasing and estimating soItware will
incorporate these hole patterns to enhance the out-oI-the-
box-ready concept Ior automated tooling applications.
Bulld quallty
SpeciIying and manuIacturing a product accurately is
essential to any lean manuIacturing operation. Graphite
blank suppliers are no exception and oIten are part oI a
critical lead-time path Ior a mold or die. This means there
is no room Ior transposed numbers or a dimension with
the wrong tolerance. Most verbal (phone orders) and Iax
communications contain dimensions and tolerances with
Iour decimal places. These orders are prime candidates
Ior error and a resulting second order, oIten at the suppli-
er`s expense and more importantly, with the delay oI an
order to a customer.
Eliminating input errors Ior the bonded product that
now has two x-, y- and z-sized pieces and twice the
tolerances was a concern. How is quality built into a
new product that is much more dimensionally complex?
Enter a new level oI soItware and customer`s experi-
ence when placing orders Ior standard blanks with Iour
decimal sizes and tolerances.
Figure 3
Several months oI testing the purchasing soItware by custom-
ers indicated minimal issues oI input error Ior materials,
sizes or tolerances. From collected data, it was agreed that an
expanded version oI purchasing soItware would be a great ft
Ior estimating and order placement oI bonded blanks.
To ensure visualization oI the new product, the soItware
was enhanced to include a simple 3D graphic model.
ModiIying the interIace screen Ior ease-oI-use with input
boxes and predefned tolerances was essential when speci-
Iying the bonded product (see Figure 3). These changes
now ensure that there is minimal chance Ior error when
estimates are perIormed or orders are placed.
The above development, advancements and elimination oI
waste could not have taken place without customer inter-
action and involvement. It is through customer/supplier
collaboration that milestones are achieved.
Create knowledge
The creation oI knowledge as previously noted also is a
principle oI lean manuIacturing. Most manuIacturing
companies use scientifc or engineered methods to solve
their problems, expand their abilities and address the next
challenge. Continuous improvement eIIorts and Ieedback
are used to increase productivity and predictability respec-
tively. Add 'tribal knowledge to the mix and an invalu-
able company knowledge base is created to be shared.
Similarly, graphite suppliers have a vast amount oI knowl-
edge at their fngertips and it, too, is best used when it is
shared. In addition to trained graphite specialists, most
graphite suppliers also have specifcation sheets Ior each
type oI graphite and other materials to assist EDM users
with their specifc needs.
The continuous review oI lean manuIacturing principles,
whether it is related to graphite or other shop consumables,
provides a great way oI asking the question, 'Are mold-
makers working with the knowledge and support oI their
suppliers to do the best job possible? Q
Dale McCartney is general manager of Ohio Carbon
Blank, Willoughby, OH. Ohio Carbon Blank is an ISO
9001.2000 certihea full service graphite proaucts manu-
facturer speciali:ing in the proauction of precision blanks
for electrical aischarge machining (EDM) applications.
The elec2roae is Ohio Carbon Blanks new bonaea graph-
ite proauct aesignea to reauce graphite electroae costs ana
is offerea exclusively via the companys GRAPHIMATOR
software. For more information regaraing the above-
mentionea software ana new bonaea Elec2roaes
, visit
www.ohiocarbonblank.com.
W page 31
33
ZZZDPEDRUJ
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Last year`s annual convention broke record attendance
numbers and this year we`re out to set a new record! At
no other time in AMBA history have more members and
partners gathered Ior one event... and many were frst-time
attendees. Don`t miss the excitement, the energy and the
opportunity to exchange inIormation with leading-edge
mold building executives at the 2013 AMBA Annual
Convention Push the Boundaries!
Slated to take place April 24-26, 2013, at the Renaissance
Hotel & Convention Center in Schaumburg, IL, the 2013
AMBA Annual Convention will showcase a dynamic
program line-up that will leave attendees energized and
ready to 'Push the Boundaries' in a number oI key areas.
Attendees will experience and discover
Operational and Financial Benchmarking Data
and Metrics
Best Ways to Improve Your Company
Plant Tour Workshops
Peer-to-Peer Exchange Forums
Sales Strategies Leading to Competitive Advantages
and So Much More
Look Ior Iull convention details in this issue on page 18.
For more inIormation on programming, speakers, sched-
ule, exhibitors, hotel and registration, visit www.amba.org.
Me &cz
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BD13 AMBA LnnwoncInn: Puh cho BnundarIo - RogIcracInn Opon
SpnnnrhIp OppnrcunIcIo tnr
cho AMBA LnnwoncInn
Several sponsorship opportunities are available in conjunc-
tion with the AMBA 2013 Annual Convention Push the
Boundaries. Scheduled to take place April 24-26, 2013, at
the Renaissance Convention Center in Schaumburg, IL,
the convention expects to draw over 200 mold building
executives. Additionally, AMBA Partners and suppliers to
the mold building industry also will have the opportunity
to exhibit at the Supplier Trade Fair all three days oI the
convention. New this year, all sponsors will be highlighted
on electronic rotating signage throughout the convention
venue to provide greater visibility throughout the entire
event! To register Ior a sponsorship or tabletop exhibit, visit
www.amba.org or contact Shannon Merrill at 847.222.9402
or smerrillamba.org. (Limited space available.)
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NnmInacInn tnr cho AMBA BD13
MnId BuIIdor nt cho Voar and
Lhapcor nt cho Voar Nnw Accopcod
Mold Bullder of the ear
Mold Builder oI the Year Nominations are now being accept-
ed Ior the 11th Annual Mold Builder oI the Year Award
(MBOY). The award was instituted to recognize outstanding
contributions made by an AMBA member. The recipient oI
this prestigious award will be an outstanding business leader,
dedicated to the industry and an active member oI the AMBA.
Last year`s Mold Builder oI the Year Award was presented to
Ralph Oswald oI Chicago Mold Engineering Co., Inc.
Chater of the ear
The AMBA Chapter oI the Year Award was established
to recognize those chapters that have made outstand-
ing contributions to the moldmaking industry. AMBA
chapters may nominate themselves or be nominated by
individuals outside the chapter. The award recipient will
be the chapter as a whole. II you believe that a particu-
lar AMBA chapter is doing positive things in the indus-
try, we encourage you to nominate it. Does the chapter
work toward implementing or maintaining apprenticeship
programs? Does your chapter work to promote moldmak-
ing in your state and nationally? These are some oI the
accomplishments that we seek Ior the Chapter oI the Year.
Tell us about it and why you believe your chapter deserves
to be the award winner.
Both the 2013 Mold Builder oI the Year and AMBA
Chapter oI the Year Award winners will be announced
during the upcoming Annual AMBA Convention in
Schaumburg, IL, April 24-26, 2013, at the Renaissance
Hotel. Announcement oI the award recipients will be
made to local newspapers, national industry publications,
The American Mola Builaer magazine and posted on the
AMBA website (award recipients are highly encouraged
to attend the convention).
The award recipients also will choose the industry-related
educational program that will receive a $5,000 scholarship
grant that will be donated by Progressive Components to
both the Mold Builder oI the Year and to the Chapter oI
the Year.
Deadline for nominations is March 1, 2013. To down-
load a nomination Iorm Ior Mold Builder oI the Year or
Chapter oI the Year, visit www.amba.org.
page 36 X
W page 35
$VVRFLDWLRQ
will Iocus on the benefts oI consistent chip load and how
it can dramatically change machining speeds and fnish
quality. Actual case studies will be presented, Iocusing on
low, medium and high RPM spindle machine tools (8-12K,
12-18K, 20K spindles).
For more inIormation or to register, go to www.amba.org/
EventCalendar.php.
Belng Preared for an 05RA lnsectlon
Wednesday, February 6, 2013, 12:00pm-12:45pm CT
Cost: No charge-AMBA members; $50-Non-members
AIter nearly a decade oI relatively lax enIorcement and an
emphasis on cooperation, OSHA, under President Obama,
announced intentions to increase inspections and citations.
ThereIore, it is now imperative your Iacility complies with
OSHA regulations and employees must know what steps
to take iI an inspector shows up. Acrisure has had success
conducting mock OSHA inspections or drills, where one
employee (a saIety director within the organization) or an
outside saIety consultant poses as an inspector and evalu-
ates the Iacility`s saIety.
Through these mock inspections, companies will gain a
basic understanding oI how an OSHA inspection works.
In-house saIety managers can conduct their own mock
inspection, making the drill more specifc to their individu-
al company's needs while saving on costly outside consul-
tant Iees. The crucial inIormation presented in this session
could help prevent heIty fnes and prepare employees Ior
an unexpected visit Irom a real inspector.
Rick Miller and Steve Vanderhill Irom Acrisure, the
AMBA-endorsed commercial insurance provider, will be
leading this webinar and will cover recent OSHA devel-
opments and how these regulations could have a negative
impact on your business. They also will cover the Iollow-
ing during the webinar:
How to know iI you are ready Ior your upcoming OSHA
inspection
What things can you do now to prepare?
What happens during an OSHA inspection?
What things are you missing in preparing Ior an OSHA
inspection?
Disgruntled employee complains to OSHA; OSHA is at
the door; now what?
For more inIormation or to register, go to www.amba.org/
EventCalendar.php.
Now WobInar trnm AMBA
1urn Fast Machlnlng lnto )$67(5 Machlnlng
1hree-Part 5erles
Part 1: (Machines with 12-18K spindles)
Wednesday, January 30, 2013, 12pm-12:30pm
Part 2: (Machines with 20K spindles)
Wednesday, February 27, 2013, 12pm-12:30pm
Part 3: (Machines with 8-12K spindles)
Wednesday, March 27, 2013, 12pm-12:30pm
Cost: No Charge
In the quest Ior Iaster machining with better fnishes,
mold and die builders continue to invest in new machine
tools, better cutters, new holding technology and attended
machining. The reality is that inconsistent chip load inhib-
its and prevents achieving Iaster machining and better
fnishes. As this cannot be seen, it most oIten is ignored
or more typically, not ever known. This three-part series
37
ZZZDPEDRUJ
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The AMBA is committed in its quest to provide compre-
hensive fnancial and operational metrics to its member-
ship. The AMBA Board oI Directors is excited to announce
that the 2nd Annual Mold Industry Benchmarking Survey
now is in progress and invites all AMBA members and
non-members* to participate and beneft Irom this intense,
data-driven study. The analysis and comparative perIor-
mance data Irom the study will prove to be invaluable
Ior evaluating and determining where opportunities lie
to grow your companies, while creating fscally stronger,
more proftable operations.
Participants Irom last year`s 2012 Benchmarking Survey
were polled and 86 percent said that the survey was helpIul
in understanding some aspect oI their business and nearly
93 percent said they will defnitely participate in the 2013
Benchmarking Survey in order to compare year to year data.
5o why benchmark?
According to Todd Finley, vice president at Commercial
Tool & Steel, Grand Rapids, MI, 'Up until the AMBA`s
Benchmarking surveys, there has never been specifc data
available Ior any mold manuIacturer to compare our busi-
ness to companies with similar dynamics. The data gave us
the opportunity to see how we measure up with the best-
in-class companies in our industry. It helped us identiIy
our weaknesses and pointed us to where we should Iocus
our improvement initiatives. The inIormation also gave us
some much needed data to assist us in making goals, iden-
tiIying metrics and measuring our progress.
To produce the report, the AMBA has teamed once again
with Business Resource Services, Inc. (BRS) oI Seattle.
Through data derived Irom the 2013 Benchmarking
Survey, participants will
Discover how your perIormance ranks side-by-
side with your peers and the top perIormers and see
where the diIIerences lie - which leads to creating
goals and action plans, and developing best practices
Enable yourselI to manage more eIIectively and eIf-
ciently by closing the gaps on world-class competition
IdentiIy your own strengths, weaknesses and areas oI
opportunity to improve proft and cash fow
Collect meaningIul data to use as a management tool Ior
owners and managers
Compare your company's perIormance to last year's
survey results (repeat participants)
Each participant will receive a copy oI the complete group
study showing perIormance oI all participants` collective
results, broken down as a whole group, by sales size categories
and by the Top 25 percent most proftable. The group study
also will contain inIormation about how to interpret and use
the data. You'll also receive a confdential, individualized
analysis oI your company's numbers compared to the group
as a whole, your sales group and the Top percent most
proftable - along with suggestions about specifc areas that
may need additional management attention.
Deadline to submit data will be March 1, 2013. In order
to have the data compiled and analyzed in time Ior our April
convention, it's critical that this deadline be met. II you did not
receive this impactIul survey via email, contact the AMBA
at 847.222.9402 or Shannon Merrill at smerrillamba.org.
*Participation is limited to those AMBA members and
non-member mold building operations that have been in
business Ior at least one year as oI their 2012 fscal year-
end (start date oI January 1, 2012 or earlier required to
participate in this study).
page 38 X
PRESENTED BY
Attend amerimold 2013 and get
connected to the people, the products
and the processes that make molds!
Register today with
Promo Code AMBA at:
amerimoldexpo.com
Donald E. Stephens Center,
Rosemont, IL
The Event for Mold Manufacturing
BD1B AMBA Wago &
BonotIc Surwog
The Winter 2012 Wage & Benefts
Survey results have been emailed to the
primary contact person at all participat-
ing AMBA member companies. This
40 page in-depth analysis oI employ-
ee benefts and wages Ior 38 diIIerent
mold shop job categories will help participants benchmark
their company and see iI their company oIIers a competitive
wage and benefts package. This survey is only available to
participating member companies and is not Ior sale. This
year`s survey had a 43-percent member participation rate!
AMBA Prnmnco cho LS MnId
Inducrg ac PLASTL Woc BD13
AMBA will exhibit at PLASTEC West 2013, February
12-14, at the Anaheim Convention Center, Anaheim, CA.
The AMBA will distribute the 2013 AMBA Sourcebook,
The American Mola Builaer magazine, 2013 AMBA
Annual Convention inIormation, AMBA Membership
and Partner inIormation and more. Stop by Booth #3999
to learn about all current AMBA initiatives, including
the 2013 Benchmarking Survey, the AMBA Scholarship
Program and the AMBA Mold Builder oI the Year and
Chapter oI the Year Nominations.
$VVRFLDWLRQ
W page 37
B1,DDD SchnIarhIp tnr Vnur
mpIngoo trnm AMBA
AMBA's National
Scholarship Program
to date has award-
ed over $216,000
nationally since the
program's inception
in 1991. The Annual
Scholarship Program continues to demonstrate AMBA's
commitment to the industry, education and oIIering
valuable member benefts. Scholarships will be award-
ed to your employees or employee dependants. The
employee has to be working Iull-time Ior your compa-
ny Ior at least one year in order to participate in the
program. Previous scholarship recipients are eligible
to apply Ior the 2013-2014 scholarships. Authorized by
the Board oI Directors, AMBA will grant up to ten (10)
$1,000 scholarships depending on the number oI quali-
fed applicants Ior the 2013-2014 school year. Schol-
arships are paid directly to the educational institution.
Applications must be submitted/postmarked by April 19,
2013. Visit www.amba.org/AMBAScholarships.php Ior
details on the program or to apply.
39
ZZZDPEDRUJ
Mombor
Montalast of North Amerlca, Frankfort, K
Derek Risk, Manager
502.848.3299 www.montaplast.com
Suitable Iorms Ior prototypes and serial tooling are made by
Montaplast oI North America, where all steps are controlled
and monitored by up-to-the-minute soItware and CNC tool
machines implement complicated contours. Geometrical data
Irom development is converted online into NC programs Ior
tools and models. Montaplast makes know-how-intensive
tools and develops the necessary manuIacturing technology.
Parcnor
ble-Bond LLC, Chandler, AZ
James Allenstein, Vice President oI Operations
480.940.0024 www.die-bond.com
Die-Bond perIorms diIIusion bonding oI conIormally
cooled molds and inserts. Using a Liquid InterIace DiIIusion
(LID) bonding process, Die-Bond joins split-layer injec-
tion molding dies containing complex conIormal cooling
passages. Its process signifcantly speeds up production
time and minimizes overall die Iabrication costs.
Kubotek U5A lnc., Marlborough, MA
Mark Parent, COO
508.229.2020 www.kubotekusa.com
Kubotek USA creates and distributes engineering soIt-
ware such as CAD, validation and change reporting. The
company is a master oI CAD model geometry, providing
3D geometry-based engineering soItware solutions. Its
advanced technologies are used in mechanical and manu-
Iacturing design, KeyCreator 3D direct CAD soItware,
supply chain communications, model validation, model
comparison and 3D CAD viewing.
Natlonal 1ool & Manufacturlng Co., Wheellng, lL
Jim Soderquist, President
847.806.9800 www.ntm.com
National Tool & ManuIacturing Co. is a one-stop shop-
ping source Ior the molding and moldmaking industries,
oIIering everything Irom standard ejector pins to complex
runnerless molding systems with precision temperature
controllers. With extensive special machining capabili-
ties and sophisticated machine tools, National can supply
virtually any standard or special component, or perIorm
any mold-related machining job, no matter how complex.
5ynventlve Moldlng 5olutlons, lnc., Peabody, MA
Greg Osborn, Account Manager
978.750.8065 www.synventive.com
Synventive Molding Solutions is one oI the world`s leading
manuIacturers oI hot runner systems and components. With a
Iocus on providing high-quality hot runner products and value
added services, Synventive delivers complete hot runner solu-
tions Ior all types oI injection molding applications.
Lhapcor Now
Chlcago
The chapter held a meeting on December 5th with Tim
RuIIner oI GPI Prototype presenting on the additive manu-
Iacturing process oI DMLS.
The chapter will host its next meeting on Tuesday, February
26. Newly-elected Illinois State Senator Michael Connelly
(Rep. 48th District) will present his insights into the
happenings in Springfeld and the eIIect the 98th General
Assembly may have on the manuIacturing industry.
West Mlchlgan
The chapter held a general membership meeting on November
13th with guest speaker David LeIere oI Bolhouse, Baar &
LeIere, PC speaking on Employment Law. Q
WoIcnmo Now Mombor and Parcnor
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Polishing System
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Gesswein is pleased to announce the latest technology in micromotor sys-
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motors and heads to create the right tool for a variety of polishing applica-
tions. With the quick disconnect feature, the operator can switch heads
within seconds. The 3
rd
generation of its kind, it has several new features
unlike previous models: convenient on/off switch, higher torque output for
heavier grinding, quick change collet and slim lightweight handpiece cable.
Visit gesswein.com for more details and all handpieces available.
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+RZ0ROGPDNHUV&DQ8VH5HVKRULQJ7RROV
WR%H0RUH&RPSHWLWLYH
By Harry Moser, Founder and President, and Millar Kelley, Research Analyst, Reshoring Initiative
M&M Tooling nc., is a complete Custom

MoId Base manufacturing facility with
capacity up to 35 x 80. We employ top
journeymen mold-makers, utilizing Mazak
CNC machining centers maintaining tight
tolerances, to achieve high quality results.
M&M Tooling nc's mission is and always
will be, to provide follow-through on commit-
ments to our customers, with personal
attention that exceeds expectations.

"Where Your Success is Our Business
395 E. Potter St.
Wood Dale, llinois 60191
Phone: 630-595-8834
Fax: 630-595-6806
Web: www.MMTOOLNG.com
Email: MMTOOLNG@aol.com
M & M TooIing Inc.
CNC Machining Specialist
Specializing in Mold Shop Overflow work
Custom MoId Bases
Wi th a personal touch
Ieur 5eurtel
Reshoring is based on simple logic: produce near the
customer. Over the past Iew decades, companies rushed
to oIIshore Ior cheap labor and low purchase price. But as
the global economy has evolved, oIIshore labor savings
have shrunk and the 'hidden costs oI producing in places
like China have become both greater and more apparent,
oIten oIIsetting the residual labor savings. OIIshore molds`
'hidden costs are more numerous and probably relatively
larger than they are Ior parts. Defciencies in a mold can
result in rework, slower cycle time, hand working oI parts,
shorter tool liIe and scrap, etc. The Reshoring Initiative,
a non-proft organization dedicated to helping compa-
nies understand the true cost oI oIIshoring (vs. domes-
tic sourcing), has developed a Total Cost oI Ownership
Estimator and is planning on a customized version
specifcally Ior molds.
China and other countries such as Portugal have taken
a direct share oI the US mold market. More important,
developing countries have taken much oI the production oI
plastic parts and fnished goods that include plastic parts.
When the plastic is shot in China, the molds typically are
sourced there. When more companies use Total Cost oI
Ownership (TCO) analysis Ior their sourcing decisions,
they will understand that they oIten do not have to give up
local manuIacturing to achieve cost targets, and much oI
this work can and will be brought back to the US.
With the adoption oI total cost analysis, US companies
are increasingly deciding to produce and source locally.
The US still is the largest market Ior most products. To
meet the needs oI the domestic market, it makes sense Ior
US companies to expand here instead oI oIIshore and Ior
Ioreign companies to locate their Iactories close to US
consumers. The moldmaking industry can use TCO analy-
sis to recapture some oI the mold market lost to imported
molds and convince US and Ioreign companies to produce
or source more plastic parts and products in the US.
A closer look at 1C0
TCO is defned as a total oI all relevant costs associ-
ated with making or sourcing a product domestically or
oIIshore. TCO includes current period costs and best esti-
mates oI relevant Iuture costs (warranty), risks (IP loss)
and strategic impacts (impact on product innovation).
The TCO Estimator can be thought oI as a more sophis-
ticated, dynamic version oI AMBA`s Finaing the Total
Cost of Your Mola ana Know the True Cost of Your Molas.
The advantage oI the TCO Estimator is that more costs
are considered, there is more supporting documentation,
the system is gaining general industrial credibility and
the results are totaled, graphed and Iorecast Ior fve years.
(Towards the end oI this article, readers will be asked
Ior their assistance in customizing the TCO Estimator to
include all or most oI the mold-specifc cost categories
in the two AMBA documents and other costs identifed.)
TCO analysis can help mold and parts companies objec-
tively identiIy, Iorecast and minimize total cost. TCO
takes into account the costs oI wages and currencies
(which are important to keep track oI, especially in low-
labor-cost countries where they oIten are rising quickly),
as well as energy and transportation prices. Other risk
Iactors accounted Ior include supply chain disruptions,
quality issues and IP theIt. Chart 1 shows the distribu-
tion oI reasons (costs) that motivated published cases oI
reshoring.
41
ZZZDPEDRUJ
Chart 1 Distribution oI Reasons Ior Reshoring
REASON NUMBER OF
CASES CTED
Wage and Currency Changes 54
Quality, Warranty, Rework 41
Delivery 38
Freight Cost 32
Travel Cost/Time or
Local Onsite Audit 27
nventory 25
Total Cost 20
ntellectual Property Loss or Risk 20
Communications 14
mage/Brand (prefer US) 12
Loss of Customer Responsiveness 9
Emergency Airfreight 9
Difculty of nnovation/
Product Differentiation 6
Natural Disaster Risk 4
Price 4
Green Considerations 4
Burden on Staff 3
Product Liability 2
Personnel Risk 1
Regulatory Compliance 1
Source: Reshoring Library 9/16/12
Row to calculate 1C0
To determine TCO Ior specifc products, molds or parts,
the user assigns a value to each oI the 36 Iactors that is
relevant to each source in the specifc case. The current
Estimator uses the Iactors to calculate 27 costs, which it
accumulates into a single total cost Ior a product sourced
Irom a particular supplier or a particular company-owned
Iactory. The user repeats the process Ior each source,
and then can objectively compare the TCO Ior the same
product Irom multiple sources, whether local or oIIshore.
The Estimator automatically generates two graphs Ior each
source: TCO - current and a fve-year Iorecast and TCO -
accumulating starting with the frmest costs such as price
and ending with the most subjective such as strategic or
green impacts.
The Iollowing list is a guide to the costs addressed in the
TCO Estimator, beginning with "hard cash" costs and
progressing to more subjective measures:
1. Cost of goods sold or landed cost: Price, packaging,
duty, planned Ireight (such as surIace shipment), logistics
Iees and insurance are included.
2. Other "hard" costs: Costs that are calculable and highly
likely to occur, include the Iollowing:
Carrying cost for in-transit proauct. Payment Ior
Ioreign products oIten occurs prior to shipment, whereas
domestic suppliers are paid aIter shipment oIten long
aIter. In-transit times are longer.
Carrying cost of inventory on-site. The amount oI on-site
inventory will be dramatically higher Ior product shipped
by ocean Ireight than Ior shipments Irom a local, just-
in-time supplier. Cycle inventory is higher due to larger,
less Irequent shipments. SaIety stock is higher due to
longer delivery times. Large inventories associated with
oIIshoring also are a risk in the next business downturn.
Prototype cost. Sourcing prototypes locally allows engi-
neers and marketing organizations to work more eIIec-
tively with the suppliers during product development.
Local suppliers typically charge less Ior the prototype iI
they also receive the production orders.
Ena-of-life or obsolete inventory. When a product
changes, oIIshore-sourced products` obsolete inventory
(in-house, en-route and on order) will be higher than
products Irom a local source.
Travel costs. Travel expense and time Ior ongoing audit-
ing and problem solving can have a notable impact on a
product's total cost.
3. Potential risk-related costs: High-Irequency risks,
such as emergency airIreight, scrap and rework, to name
a Iew, can be calculated based on past experience with
an existing supplier. New products or new suppliers will
require estimates.
Rework. These costs can be especially high Ior custom
products, such as molds or dies.
Quality. Who pays Ior scrap? In addition to the cost oI
lost production and warranty-related payouts when the
product Iails, quality problems are costly in other, less
tangible ways, such as lost market share, permanent loss
oI customers or the negative impact on brand image.
Proauct liability. How do the suppliers compare in
terms oI accessibility, willingness and ability to pay any
product-liability claims?
page 42 X
Intellectual property risk. Approximately fve to seven
percent oI world trade consists oI counterIeit or pirated
goods.
1
Opportunity cost. What is the cost oI lost orders and
customers when a supplier cannot respond quickly
enough to changes demanded by the market?
Brana image. Several recent surveys have shown an
increasing preIerence Ior domestically made products
and decreasing preIerence Ior Chinese products. These
changing attitudes are based on improving quality oI
US products, publicity about poor quality imports and
recognition oI domestic manuIacturing`s impact on the
economy, neighbors and Iamily.
Economic stability of the supplier. It is much easier to
fnd accurate inIormation about the stability oI a suppli-
er located in the home market than it is Ior a supplier
overseas. Lower tier suppliers are especially hard to
monitor in developing countries.
Political stability of the source country. Even countries
that are making good economic progress can become
destabilized because oI changing consumer expecta-
tions and demands, as well as political unrest.
4. Strategic costs:
Impact on innovation. Separating manuIacturing Irom
engineering degrades the innovative eIIectiveness oI a
company and its home country. Conversely, 'cluster-
ing (having suppliers, research universities, manuIac-
turing, development and production located near each
other) provides a large advantage Ior innovation.
Proauct aifferentiation ana mass customi:ation. It is
easier and less costly to make the move to mass custom-
ization with short, tightly clustered supply chains
5. Overall impact on society: The current TCO Estimator
calculates the micro-economic impact on the frm. The
Reshoring Initiative is developing two additional Ieatures
to estimate the broader impact on society:
Environmental. Some companies measure the 'cleanli-
ness oI their own production and their supply chains.
"Green" costs now can be manually inserted into the
TCO Estimator. A green calculation will be added to
a Iuture version oI the TCO Estimator. Green issues
will become more important as the population contin-
ues to grow, impacting sustainability. As a result, it is
likely that hard costs, such as carbon taxing, rather than
voluntary estimates may increasingly apply in this area.
Macro-economic. Reshoring increases US employ-
ment and business activity in domestic suppliers. This
Ieature will value reshoring`s impact by summing the
extra taxes that workers and companies will pay and
the lower government expenditures Ior unemployment,
Iood stamps, welIare and stimulus programs.
1he lmact of uslng 1C0
Digital Innovations reshored and outsourced plastic
molding. WHAM-O reshored molding in-house. Wright
Engineered Plastics has reshored as a custom molder.
Numerous companies across all sectors oI manuIacturing
have reshored or have committed to bring work back to
the US. To see a sampling (with links to its published arti-
cles) oI some oI the 200 companies that have announced
reshoring, visit www.reshorenow.org/book/table.
User data shows that about 25 percent oI what has been
oIIshored would come back iI all companies used TCO
instead oI price Ior sourcing decisions. The impact oI
using TCO is demonstrated by a statistical analysis oI user
calculations. The results Ior the most recent 27 cases oI
China vs. US are in Chart 2.
Chart 2 Summary oI Users` TCO Results: China vs. US
1
"Knock-oIIs catch on," The Economist, March 4, 2010.
Comparison US % of % of cases where
Basis China Price or US has the
TCO, average advantage
Price 169% 15%
TCO 96% 56%
Difference 73% 41%
From this data, it could be concluded that the use oI TCO
instead oI price changes the sourcing decision to domestic
Irom oIIshore on 41 percent oI the cases. For Iorecasting
the impact oI universal TCO usage, the Initiative conserva-
tively reduces that fgure to 25 percent.

Based on analysis oI the articles in the Reshoring Library,
the Initiative calculates that about 50,000 manuIacturing
jobs have been reshored in the last three years. That surge
represents about 10 percent oI the total increase in manu-
Iacturing jobs since the low oI January 2010. II the current
trend oI increased TCO use is paired with other Iavorable
trend Iactors or strategies, the potential Ior reshored jobs is
estimated at up to six million in Chart 3.
W page 41
43
ZZZDPEDRUJ
Chart 3 Potential Ior Reshored Jobs
Scenario Manufacturing TotaI Jobs**
(Source of the scenario)* Jobs*
Today: f all companies
used TCO ~500,000 1,000,000
(Reshoring nitiative)
By 2015: f Chinese
wage trends continue 1,000,000 2,000,000
(~Boston Consulting Group)
Better US training,
process improvement,
automation, tax rates 2,000,000 4,000,000
(~Advanced Manufacturing
Partnership)
End of offshore currency
manipulation 3,000,000 6,000,000
*# of jobs and scenarios are cumulative
**Assumes a low 1.0 multiplier effect
When it becomes clear that domestic TCO is at least
as low as oIIshore TCO, it is easier Ior a company
to place more emphasis and resources on building
strategies such as product diIIerentiation or innova-
tion, both oI which are maximized via local sourcing.
A company might pursue cost-reduction programs such as
lean, theory oI constraints (TOC), design Ior manuIacture
and assembly (DFMA), quick response manuIacturing
(QRM), automation or training that might have seemed
insuIfcient to close a 40-percent price gap but are more
than able to close a 10-percent TCO gap.
TCO use and industry awareness oI the potential benefts
oI reshoring are essential components oI rebuilding the US
industrial base.
To fnd out more about how all segments oI US society
can help reshoring and the US industrial base, see the
Behavioral Change Suggestions/Call to Action chart at
www.reshorenow.org/amba.
The advantages oI producing near the consumer are
great. The global economy is expected to become Iar
more complex and high-paced than what we are used to.
Education, fexibility and innovation are key attributes Ior
success in the coming years. It is no surprise that the need
Ior these attributes also helps drive companies to reshore.
Loss oI fexibility and reduced ease oI innovation (along
with subsequent increased intellectual property theIt) are
among the important hidden costs oI oIIshoring. Keeping
manuIacturing local helps keep engineering Irom Iollow-
ing manuIacturing oIIshore. Education, especially train-
ing a skilled workIorce, is the single most important
controllable Iactor in rebuilding a solid manuIacturing base.
The Reshoring Initiative is working with the US Department
oI Labor to address the skilled workIorce shortage.
The Reshoring Initiative believes that the Iastest, most cost
eIIective, stable way to strengthen the domestic moldmak-
ing industry and the economy as a whole is to motivate
and enable reshoring and help companies see the benefts
oI not oIIshoring. With greater TCO use, by customizing
the TCO Estimator Ior molds and by promoting success-
Iul reshoring cases, the moldmaking industry can recover.
The Reshoring Initiative is ready to assist moldmakers and
their customers with TCO analysis and to provide public-
ity Ior reshoring successes! The Initiative looks Iorward to
hearing Irom you. Q
+RZ0ROGPDNHUV&DQ8VH
7&2DQG5HVKRULQJ
Use TCO Ior sourcing and selling (convince your
customers to buy based on TCO, not price).
Report your reshoring successes, such as making
molds that a Iew years ago would have gone oIIshore,
on our Case Studies Ieature: www.reshorenow.org/
resources/cases/
Help us build a mold-specifc version oI the TCO
Estimator. (The customized estimator will be posted
on the Initiative website and linked Irom the AMBA
website Ior use by moldmakers and their custom-
ers.) To help develop a customized TCO version Ior
molding, go to www.reshorenow.org/amba.
Use the Reshoring Library to identiIy prospects.
OEMs that reshore are more committed to keeping
production here and may need new sources now.
Use the success oI reshoring to motivate local manu-
Iacturing skills training programs.
For more information on the Reshoring Initiative, contact
Harry C. Moser, founaer ana presiaent, at 847.726.2975,
harry.moserreshorenow.org or visit www.reshorenow.org,
blog. www.reshorenow.blogspot.com, Twitter. reshorenow,
Facebook. www.facebook.com/ReshoreNow or LinkeaIn.
Reshoring Discussion Forum.
,QGXVWU\
M & M 1oollng Recelves 2012 Award
M & M Tooling, Wood Dale, IL, has
been selected Ior the 2012 Best oI
Wood Dale Award in the Tool & Die
Maker Equipment & Supplies catego-
ry by the Wood Dale Award Program.
Each year, the Wood Dale Award
Program identifes companies that
have achieved exceptional marketing
success in their local community and
business category. These are local companies that enhance
the positive image oI small business through service to their
customers and the community. These exceptional companies
help make the Wood Dale area a great place to live, work
and play. The 2012 Wood Dale Award Program Iocuses
on quality, not quantity. Winners are determined based on
the inIormation gathered both internally by the Wood Dale
Award Program and data provided by third parties. Visit
www.mmtooling.com Ior more inIormation.
Polymer Converslons 0ens Clean Room xanslon
Polymer Conversions Inc.
(PCI), Orchard Park, NY,
recently announced the
completion oI the last
step oI its expansion,
which started in 2007.
The plastics technology
center frst opened in 1979. Since then, it has grown to
Iocus primarily on healthcare products. Just beIore the
new year, Polymer Conversions opened 15,000 square
Ieet oI Class 8 (100,000) clean room manuIacturing space.
This space grows the company`s production capacity by
over 50 percent. The expanded clean room space supports
PCI`s continued emphasis on contract manuIacturing servic-
es Ior the healthcare industry. For more inIormation, visit
www.polymerconversions.com.
5eco 1ools Recognlzed Natlonally for Best
Ruman Resources Practlces
Seco Tools, Troy, MI, Ior the second year in a row, was
named one oI the nation`s 'Best and Brightest Companies
to Work For by the National Association Ior Business
Resources (NABR). Seco, a leading provider oI advanced
metal cutting solutions Ior the manuIacturing indus-
try, received the honor Ior upholding the highest quality
human resources initiatives, including employee engage-
ment, work-liIe balance, open-door policies, training
programs and employee events. According to Dan Sikora,
director oI operations and human resources Ior Seco, the
company makes recruiting and retaining talented employ-
ees a top priority, which is critical in a time when skilled
workers within the manuIacturing sector are at a premium.
Seco oIIers several programs to reward dedicated, respon-
sible and creative employees, as well as Iosters an environ-
ment that listens to employees. In addition to this national
recognition, Corp' Maga:ine recently listed Seco as one oI
'Metropolitan Detroit`s 101 Best and Brightest Companies
to Work For Ior the Iourth year in a row. For more inIor-
mation, visit www.secotools.com.
Free 1echnlcal 5emlnar on Advanced Materlals
and Processes
CraIts Technology, Elk Grove Village, IL, is hosting a Iree
technical seminar on Advanced Materials and Processes.
The seminar will be held on May 8, 2013, and October
9, 2013, at its Elk Grove Village location. The seminar is
designed to provide technical inIormation on cemented
tungsten carbide and advanced ceramic materials. The team
oI experts will address all oI the properties oI the materi-
als, examples oI applications and benefts. The team will
discuss modes oI Iailure and how proper grade selection
plays a major role in solving wear and corrosion problems
in the manuIacturing process. This halI-day event is Iree to
qualifed enrollees. To attend, visit www.craItstech.net or
contact David LeMaistre at 847.758.3100.
vero 5oftware Acqulres 5escol lnternatlonal
Vero SoItware, a leading provider oI CAD/CAM/CAE
solutions, is pleased to announce the acquisition oI Sescoi
International, an industry specialist in 2D to 5-axis NC
machining with its WorkNC product suite. The acquisition
oI Sescoi International frmly establishes Vero as the world`s
largest and number one CAM specialist. The acquisition
will provide the platIorm to build even stronger products
across the range through a signifcantly enlarged develop-
ment team and distribution channel with experienced, time-
served industrial knowledge. For more inIormation, visit
www.verosoItware.com.
GF AgleCharmllles Chamlons Commonwealth
Center for Advanced Manufacturlng
GF AgieCharmilles, Lincolnshire, IL, now is collaborating
with the Virginia-based Commonwealth Center Ior Advanced
ManuIacturing (CCAM) to help accelerate the transIer oI
research innovation Irom the laboratory to commercial use.
CCAM is a research center that brings global manuIactur-
ing companies together with Virginia`s top research univer-
sities and CCAM`s expert engineers and scientists. As one
oI CCAM`s newest industry members, GF AgieCharmilles
aids in guiding research that Iocuses on surIace engineer-
ing and manuIacturing systems. GF AgieCharmilles also
has supplied CCAM with a FO 550 sp die-sinking EDM
system Ior a machining cell that will assist CCAM`s indus-
try and university members in turning research into business
advantages. The FO 550 sp is part oI GF AgieCharmilles`
45
ZZZDPEDRUJ
Quoting and ordering EDM graphite is easier
than ever using our free Graphimator software.
The Graphimator now oers our new
bonded graphite Elec2rodes featuring
out-of-the-box-ready blanks with optimized
material usage.
Turn your quotes into orders with only a few
keystrokes. There is no other system like it.
Call, log on, or scan the QR code to begin
streamlining your graphite ordering today.
Advancing Graphite Technology
www.ohiocarbonblank.com
800-448-8887
*UDSKLWHDW<RXU)LQJHUWLSV
Watch our video to see
how Elec2rodes
will save you
time and money!
Scan to start quoting
and ordering graphite
rectangles, rounds, and
Elec2rodes today!
'Speed Edition oI die-sinking machines, allowing users to
increase productivity and achieve fne, even-polished surIace
fnishes with unequalled consistency on both small and large
surIace areas. For more inIormation, visit www.gIac.com/us.
nglneerlng 5tudents 1our Rarrls & Bruno
Rocklin High School engi-
neering students recently
toured the Harris & Bruno
International, Roseville, CA,
manuIacturing Iacility. 'Seeing
operation oI the 5-axis CNC
machine, the water jet mach-
ine and all the equipment
was the best part oI the
tour, said Senior Hugo Le Rouzo, 17. Hugo, who is
planning to pursue an engineering degree, continued,
'It`s good to see what you`re going to do. RHS teacher Dan
Frank reported that his Iavorite part oI the visit was when
students` eyes darted to him with a new understanding oI the
real-liIe applications oI their classroom activities. 'It was so
benefcial Ior our students to be able to talk with adults in
the engineering and machining industry so that they could see
themselves in these proIessions, said Frank. In addition to
touring the Iacility, meeting engineers and talking to employ-
ees about the equipment they operate, students benefted Irom
advice Irom Harris & Bruno managers. For more inIormation
on Harris & Bruno, visit www.harris-bruno.com.
Non-Prot Provldlng nglneerlng Courses for
Future nglneers
Project Lead the Way (PLTW) is the leading provider oI
rigorous and innovative Science, Technology, Engineering,
and Mathematics (STEM) education curricular programs
used in middle and high schools across the US. "Research
shows that the American economy will add 1.2 million new
STEM-related jobs by 2018, said Dr. Vince Bertram, presi-
dent and CEO oI PLTW. 'It is critical that we equip today`s
students with the knowledge, critical thinking and problem-
solving skills they need to fll these jobs and be prepared Ior
the global economy. Through rigorous curriculum, hands-
on classroom activities and real-world experiences, PLTW
engages students in activities, projects and problem-based
learning. Students create, design, build, discover, collabo-
rate and solve problems while being exposed to areas oI
study that they typically do not pursue. The curriculum,
delivered through PLTW's Virtual Academy and cited by the
Harvard Graduate School oI Education as a 'model Ior 21st
century career and technical education, is provided Iree oI
charge to schools that register with PLTW. For more inIor-
mation about Project Lead the Way, visit www.pltw.org, call
877.335.7589 or email schoolsupportpltw.org. Q
6KRZ3UHYLHZ
Connect with over 2,000 suppliers and thousands oI attendees at PLASTEC West February 12-14, 2013, Anaheim
Convention Center, Anaheim, CA. At this nationwide resource Ior plastics processing proIessionals, attendees can source
the Iull spectrum oI machinery, technology and services Ior the plastic industry including primary processing machinery,
contract services, material handling/logistics, computer-aided design and manuIacturing, materials, molds and mold
components, enterprise IT, production machinery, automation technology and much more! Visit www.PLASTECWest.com
Ior more inIormation.
The Iollowing PLASTEC West 2013 exhibitors may be oI interest to The American Mola Builaer readers:
Amerlcan Mold Bullders Assn. (AMBA)
Booth #3999 www.amba.org
AMBA is the premier trade association Ior the US
mold manuIacturing industry, serving its members with
fnancial and operational metrics, cost-saving programs,
educational resources and so much more. Membership
inIormation, the 2013 AMBA Sourcebook and the latest
issue oI The American Mola Builaer will be available at
the AMBA booth.
A51 1echnology GmbR
Booth #3801 www.ast-tech.de
AST Technology will demonstrate the latest edition oI
its CVe Monitor System, which now oIIers users the
opportunity to drive comprehensive mold management in
10 languages, as well as its Iull array oI services including
Design Ior ManuIacturing (DFM), standard tooling and
engineering, process development and optimization and
assessment and training.
Crystallume
Booth #3535 www.crystallume.com
Crystallume will showcase cutting tools and coating
services Ior the moldmaking industry.
bM
Booth #3961 www.dme.net
DME oIIers the industry`s broadest range oI market-
leading products, a global logistics inIrastructure and
a support organization unrivaled Ior its ability to assist
customers. DME oIIers a complete line oI standard and
special mold bases, MUD quick-change mold systems,
mold components, moldmaking equipment and supplies,
hot runner systems, control systems and technical services.
bM5
Booth #3921 www.dmscomonents.com
DMS supplies mold component/bases to the moldmaking
industry, as well as many other supply-related products,
such as Koolfow water maniIolds, mold plaque, IMM
solutions, specialty components, platen guard locating
rings and REDEvault, etc.
lncoe
Booth #3946 www.lncoe.com
Since its inception in 1958, Incoe has strived to deliver
the best price/perIormance ratio in hot runner solutions
available with superior service. Proven technologies like
Direct-Flo Gold hot runner systems and Unitized Leak-
ProoI Systems provide molders with advanced processing
advantages, improved part quality, part-to-part consistency
and robust design perIormance.
lndustrlal Molds Grou
Booth #3954 www.lndustrlalmolds.com
Established in 1968, Industrial Molds has earned an
excellent reputation as a precision mold manuIacturer,
designing and building molds Ior thermoplastics, thermoset,
die-cast and insert precision applications. This reputation
is evidenced by the company's capabilities, expressed in
terms oI the markets that it serves, its engineering expertise
and its manuIacturing capability.
5tretch our Budget - Attend
PLA51C West to Comare 5ullers
47
ZZZDPEDRUJ
Maklno
Booth #2869 www.maklno.com
Makino is a global manuIacturer oI high-speed CNC
horizontal and vertical machining centers and Ram and
Wire EDMs. Its many patented technologies and process
innovations help tool, die and mold manuIacturers reduce
cycle times and lead times and improve accuracies and surIace
fnishes. Makino provides technology transIer training to
help moldmakers compete in the global marketplace.
Mold-Masters Llmlted
Booth #4163 www.moldmasters.com
Established in 1963, Mold-Masters is a privately-held
global company and the world's leading supplier oI hot
runner technology and systems. Mold-Masters designs,
manuIactures and supports a Iull range oI hot runner
products, including hot runner systems, temperature
controllers, hot halves and gating technologies. Mold-
Masters always is looking to deliver the ultimate in melt
delivery and control systems.
Mold Craft, lnc.
Booth #1506 www.mold-craft.com
Since 1964, Mold CraIt, Inc. has established itselI as an
industry leader in the design and manuIacture oI plastic
and MIM injection molds. Specializing in high-volume,
multi-cavity and multi-mold programs with complete
interchangeability, Mold CraIt is committed to tolerances oI
+.0001 and serves the medical, dental and consumer markets.
MR Mold & nglneerlng
Booth #1346 www.mrmold.com
M.R. Mold is an industry expert in plastics, liquid silicone
and gum stock rubber injection and compression molds.
Each mold is tested and sampled within the company`s
Tech Center. M.R. Mold`s cold runner system oIIers
customers substantial cost savings.
0hlo Carbon Blank (0CB)
Booth #4311 www.ohlocarbonblank.com
A recognized leader in the manuIacturing oI graphite
electrodes Ior the EDM industry, Ohio Carbon Blank
oIIers the Iree, online GRAPHIMATOR, allowing users to
generate quotes and order precision graphite components
24/7. OCB`s new elec2RODE bonded graphite product
minimizes material use, eliminates milling oI blanks Ior
work holding and reduces graphite costs.
PC5 Comany
Booth #3920 www.cs-comany.com
PCS is a leading Iull-line supplier oI high-quality molding
components, standard and special mold bases, hot runner
systems, custom-made products and nanotechnology
products. The company is positioned to provide customers
with consistent quality, exceptional customer service and
component inventory. For more inIormation about PCS
and its products, visit the company's website.
Poco Grahlte
Booth #3921 www.oco.com
Poco Graphite, an industry leader in EDM graphite, has
extended its high-end, perIormance-based material system
to include solutions targeted at increasing the liIe oI plastic
injection mold components. The UltraC DLC Iamily oI
coatings will substantially enhance the durability oI mold
components, reduce Iriction and increase the run liIetime.
Progresslve Comonents
Booth #3801 www.rocoms.com
At PLASTEC West, Progressive will Ieature its new
Z-Series alignment locks, proven to show no wear even
aIter two million cycles; liIters; CAM actions and latch
locks just some oI the many mechanical solutions oIIered
Ior part release and alignment. New brass cooling items
and more also will be highlighted.
Roehr 1ool Cororatlon
Booth #3801 www.roehrtool.com
Roehr will Ieature its DT collapsible core at PLASTEC West,
as well as its new, patent-pending DT core retention sleeve,
which ensures more reliable ejection and Iaster cycle
times. Roehr also will highlight its ProtoBridge System
and other products, including the RT series collapsible
cores, expandable cavities and minicores.
1oollngbocs LLC
Booth #3801 www.toollngdocs.com
ToolingDocs is a leading authority on mold maintenance,
Ieaturing multi-level maintenance certifcation training in
both English and Spanish at its Mold Maintenance Training
Center in north central Ohio and additional locations in
North America. Other products include Maintenance
Capability Assessments (MCA), On Site Training (OST)
and Total Systems Implementation (TSI). Q
Over the last Iour or fve years, I have seen several mold
businesses close because their customers did not pay
Ior dies. On the other hand, I also have been a part oI
successIully keeping the doors oI mold businesses open
by eIIectively utilizing the Michigan Mold Lien Act.
The Michigan Mold Lien Act, which was enacted in
2002 (there also are similar statutes in Ohio, Indiana and
Illinois) grants a mold builder the right to establish a non-
possessory lien on tooling it designs and manuIactures.
Over the last ten years, the Michigan Mold Lien Act has
provided an eIIective remedy to mold builders to enIorce
a lien aIter dies has been delivered to a customer iI Iull
payment has not been received.
During the recent economic downturn, many mold build-
ers put lien procedures in place to make sure that the
strict procedures under the Michigan Mold Lien Act were
being Iollowed. It looks as iI the US economy may fnally
have taken a turn Ior the better and mold businesses are
getting back to work. During these 'good times, it is
easy to Iorget or to get complacent about Iollowing the
strict procedures under the Michigan Mold Lien Act.
However, as many businesses learned over the last Iew
years, it only takes one instance oI non-payment to put
your business at serious risk. II the procedures under the
Michigan Mold Lien Act are not specifcally Iollowed, a
mold builder runs the risk oI not having the protections.
6WUDWHJLHV
Key Iactors to remember when fling a lien under the
Michigan Mold Lien Act (and the similar mold lien laws
in Ohio, Indiana and Illinois) are as Iollows:
'Permanently record the mold builder`s Iull legal name
and address on every die prior to shipping. A recent opinion
by the Michigan Court oI Appeals, C.G. Automation &
Fixture, Inc. v. AutoIorm, Inc., 2011 Mich.App.Lexis 89,
clarifed the provisions oI the Michigan Mold Lien Act
by holding that in order to have an enIorceable lien on
dies, the mold builder must aIfx "permanently recorded
inIormation" to each die, on the actual body oI the die
itselI. The inIormation required is the mold builder`s
Iull legal name and address. In this C.G. Automation &
Fixture, Inc. v. AutoIorm, Inc. case, the Michigan Court
oI Appeals Iound that C.G. Automation & Fixture, Inc.`s
identifcation tags aIfxed to 'removable risers that
were mounted to the dies were insuIfcient. The Court,
in overruling the trial court, held that C.G. Automation
& Fixture, Inc. did not have an enIorceable lien on the
dies because it had Iailed to 'permanently record the
required inIormation on the dies when it aIfxed the
inIormation to the risers, 'an object readily removable
Irom the die. ThereIore, the recording must be perma-
nent. It is recommended to engrave the required inIor-
mation directly on to the body oI the die and, as set Iorth
below, take a digital photo oI the recording.
Prior to shipping dies, take a digital photo oI all the dies
that includes evidence oI the permanent recording oI the
mold builder`s name. The Michigan Court oI Appeals`
decision in C.G. Automation & Fixture, Inc. v. AutoIorm,
Inc. raises the question oI what is considered permanent
(the Court did not specifcally identiIy what it considers
permanent). Almost anything can be removed Irom a die
with enough eIIort. The best way to combat this issue is
to take digital photos oI all dies with the recording prior
to shipping the dies. This way, iI the recording is taken
oII or removed, the mold builder has evidence that the
recording was on the dies when they were shipped to the
customer. C.G. Automation & Fixture, Inc. did not have
photos oI the recordings to support its position that the
recordings were 'permanently on the dies.
(QIRUFHDEOH0ROG/LHQV5HTXLUH
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By David Lefere, Bolhouse, Baar & Lefere, PC
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49
ZZZDPEDRUJ

When fling UCC Financing Statements, mold builders
must use the customer`s exact legal name registered with
the state oI incorporation. A fnancing statement that
Iails to contain a customer`s exact name may be Iound
to be seriously misleading and thereIore deIective. MCL
440.9506(2). In Crestmark Bank v United States (In re
Spearing Tool & MIg) 302 BR 351, the United States
District Court Ior the Eastern District oI Michigan Iound
that a creditor did not take priority over another secured
creditor because the customer`s name on the UCC
Financing Statement was not the exact registered name.
ThereIore, it is extremely important Ior mold builders to
Iully research the customers to make sure that the proper
registered name is being used in the UCC Financing
Statements fled.
PerIect liens (fle UCC Financing Statements and record
on dies) prior to shipping dies. All UCC Financing
Statements should be fled prior to shipping to ensure
frst priority oI the lien. In Delta Engineered Plastics
LLC v Autolign ManuIacturing Group Inc, 286 Mich
App 115 (2009), the Michigan Court oI Appeals Iound
that a molder`s lien under the Michigan Mold Lien
Act had priority over a lender`s blanket security inter-
est. One oI the key Iactors to this fnding is that the lien
was timely placed on the molds. It can be interpreted
Irom the Delta Engineered Plastics LLC case that as
long as a mold builder Iollows the strict procedures oI
the Michigan Mold Lien Act and perIects the lien prior
to shipping dies, that it also will have frst priority over
lenders and other potential claimants.
It is recommended to fle liens on all tooling, not just
tooling that you think may have a problem in the end.
This will ensure that liens are fled iI/when a mold
builder has a collection issue arise.
SuccessIully creating and enIorcing a lien under the Michigan
Mold Lien Act can make the diIIerence between being paid
in Iull and receiving nothing when a customer or supplier
becomes insolvent. To take Iull advantage oI the benefts oI
the Michigan Mold Lien Act, a mold builder must ensure
that it is specifcally Iollowing the strict procedures under
the statute. This only can be done with a clear understanding
and working knowledge oI the Michigan Mold Lien Act or
the similar mold lien laws in Ohio, Indiana and Illinois. Q
Davia Lefere is a partner with the Granaville law hrm
of Bolhouse, Baar & Lefere. His practice areas incluae
Business ana Employment Law, Commercial Litigation ana
Creaitors Rights with special emphasis on lien law. He can
be reachea at aavialbolhouselaw.com or 616.531.7711.
moldmasters.com
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Mold-Masters and the Mold-Masters logo are trademarks of Mold-Masters (2007) Limited. 2012
Mold-Masters (2007) Limited. All rights reserved.
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PLASTEC West 2013, February 12-14,
Anaheim, CA, 310.445.4200,
www.PLASTECwest.com
AMBA Plant Tour Workshop, February 14,
Prestige Mold, Rancho Cucamonga, CA,
847.222.9402, www.amba.org
0$5&+
PLASTEC South/MD&M Southeast 2013,
March 6-7, Orlando. FL, 310.445.4200,
www.PLASTECsouth.com
$G,QGH[
Alliance Laser Sales .................................................... www.thenewonesource.com ............................ Inside Back Cover
Alliance Specialites ..................................................... www.thenewonesource.com ......................................................17
AMBA......................................................................... www.amba.org ..........................................................................15
amerimold ................................................................... www.amerimoldexpo.com ........................................................38
A. Finkl & Sons Co. .................................................... www.nkl.com .........................................................................11
CAE............................................................................. www.caeservices.com ...............................................................27
CGS North America, Inc. ............................................ www.camtool.com .....................................................................36
Clinton Aluminum ...................................................... www.ClintonAluminum.com ....................................................33
Crystallume Engineered Diamond .............................. www.crystallume.com ...............................................................35
Delcam ........................................................................ www.delcam.com ......................................................................16
DME ............................................................................ www.DME.net ...........................................................................14
Dynamic Surface Technologies .................................. www.dynablue.com ........................................ Inside Front Cover
Ellwood Specialty Steel .............................................. www.ess.elwd.com ....................................................................16
Erowa Technology, Inc. .............................................. www.erowa.com ........................................................................13
Gesswein ..................................................................... www.gesswein.com ...................................................................39
HAAS Corporation ..................................................... www.HaasCNC.com .................................................................25
Incoe Corporation ....................................................... www.incoe.com .........................................................................31
M & M Tooling, Inc. ................................................... www.mmtooling.com ................................................................40
Makino ........................................................................ www.makino.com/diemold .........................................................5
Millstar, LLC .............................................................. www.millstar.com .......................................................................9
Mold-Masters .............................................................. www.moldmasters.com .............................................................49
Mold-Tech ................................................................... www.mold-tech.com .................................................................35
Ohio Carbon Blank, Inc. ............................................. www.ohiocarbonblank.com .......................................................45
PLASTEC West .......................................................... www.PLASTECwest.com .........................................................29
Plastic Engineering & Technical Services, Inc. .......... www.petsinc.net ........................................................................10
Progressive Components ............................................. www.procomps.com/cve ............................................Back Cover
Rocklin Manufacturing Co. ........................................ www.rocklinmanufacturingco.com ...........................................15
SCHMOLZ + BICKENBACH USA, Inc. .................. www.schmolz-bickenbach.us ....................................................24
Superior Die Set Corporation ...................................... www.superiordieset.com ...........................................................34
Ultra Polishing Inc. ..................................................... www.ultrapolishing.com ...........................................................28
Wisconsin Engraving Co. Inc. / Unitex ...................... www.wi-engraving.com ..............................................................9
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$35,/
2013 AMBA National Convention, April 24-26,
Schaumburg, IL, 847.222.9402, www.amba.org
-81(
amerimola 2013, June 12-13, Rosemont, IL,
513.527.8800, www.amerimoldexpo.com
6(37(0%(5
PLASTEC Midwest 2013, September 10-12, Chicago, IL,
310.445.4200, www.PLASTECmidwest.com
51
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When Tooling Engineers visil lheir suppliers, accessing nold drawings and
perornance dala is dicull and il can be nearly inpossible lo oblain when
lhey are nol nearby. Progressive's new CVe Monilor provides:
Cycle line noniloring lo veriy consislenl parl qualily and cosl
Mainlenance aclivily lracking lo reduce unscheduled nold sloppages
Reporls accessible lo Tooling Engineers wherever lhe nold is run
Along wilh perornance hislory, drawings and selup sheels are slored on lhe unil's
2CB ash drive. And, wilh all o lhis capabilily lling inlo lhe sane pockel as lhe
world's nosl popular cycle counler, your nold specs are ready or an upgrade.
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J\\Gifî\jj`m\:fdgfe\ekjXk1GcXjk`Zj:Xgj:cfjli\j)'()sD;DDèe\Xgfc`js<ogfgcXjks<lifdfc[s
LEARN MORE ABOUT THE CVe
FROM INDUSTRY EXPERTS AT
WWW.PROCOMPS.COM/CVe

2013 The American Mold Builder - Winter

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2013 The American Mold Builder - Winter

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