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MGS News 2008 11-2008: MGS Expands Production at its ISO Class 8 Clean Room Facility November 2008: MGS Expands Class 8 Clean Room Facility The company is building dedicated manufacturing space to house the production of a new, custom drug delivery device. The manufacturing cell will include three multishot (multiple material) injection molding machines dedicated to providing in-mold assembly technologies and downstream automated packaging systems to minimize costly and variable secondary operations. The customer for whom MGS Antioch is manufacturing these components is a major pharmaceutical manufacturer. The production launch is scheduled for January 2009. MGS Antioch has an ISO Class 8 Clean Room with 13 fully multishot capable work stations with presses ranging from 45-220 tons, providing the medical/healthcare industries with one of the largest concentrations of advanced resources for multi-resin manufacturing in North America. The company also has 12 presses designated for injection molding in its white room. -------------------- October 2008: MGS Assures Accuracy with Haimer To ensure high-accuracy from its machines and extend the life of its high-end cutting tools, MGS elected to use tool holders and a power clamp shrink fit machine from Haimer USA. "We were buying high-precision, five-axis machines with nearly 20,000 rpm on the spindles," says Berg. "We decided to go with a reputation for quality, because all of the tooling we have is high-precision tooling that we'd want to use with a shrink-fit system." "There were alternative shrink-fitting systems", notes Berg, "but meshing these tool holders with the shrink fit machines made perfect sense. We wanted to get something in here that would help the holders last longer. The best solution, after evaluating all the options, was the speed and the ease of use, no matter what setting or size. It provides consistent heating and cooling and a wide range of capabilities from small to very large holders." These shrink-fit systems use high frequency and high power to quickly heat the tool holder for quick tool removal and insertion. Using an intelligent coil, the system adapts to the chuck, distributes heat more evenly and only heats the collet area of the holder, which decreases the time it takes to cool down and is gentler on the tool. -------------------- August 2008: MGS Mfg. Group Advances With 5-Axis Technology “The capabilities provided by this 5-axis machine have increased efficiencies in our tool shop”, says Dan Anderson, High Speed Machine Specialist for the MGS Mfg. Group. “It allows us to cut more accurately, rigidly, and at a faster pace.” He continues, “After testing different machines from various manufacturers, röders was found to be among the most precise and provided the latest technology for our current and projected needs. We have a successful history utilizing the röders 3-axis machines, so it made sense to stick with a brand name we trust.” The PC-based machine provides the company with the flexibility to monitor production and schedule projects from an off-site location. The system software allows MGS to schedule projects in advance to accommodate the required number of days as appropriate to the project. From a mechanical standpoint, the machine utilizes linear motors in lieu of ball screws, making it a more durable machining center. The machine is capable of cutting both graphite and steel. In the pursuit of continually improving its manufacturing processes, MGS Mfg. Group plans to acquire another 5-axis machine by the end of the year. -------------------- July 2008: MGS Raises Awareness For Local Charities Participating charities included the Milwaukee Rescue Mission, Friends of Abused Families (262-255-9488), Full Shelf Food Pantry Inc. (262-335-0685), Hartford Food Pantry, Sussex Food Pantry, and St. Boniface/St. Gabriel Food Pantry. The food pantries provide food and personal items to those in need of such items, while Friends of Abused Families strives to eliminate domestic violence by providing crisis intervention services. The Milwaukee Rescue Mission provides food, shelter and outreach programs for the homeless and underprivileged. The event was a huge success, raising thousands of dollars in monetary donations and over 3,000 lbs. of non-perishable food and personal care items. According to John Berg, Marketing Director for MGS, “We were thrilled with the turnout and very pleased with the generosity of our employees and the businesses in our community. We definitely plan on repeating this event in 2009, and hope to make it even more successful by inviting neighboring Germantown businesses to participate“. Together with the company’s employees and their families, other event attendees included Wisconsin Congressman Jim Sensenbrenner and Wisconsin State Senator Alberta Darling. MGS Mfg. Group sincerely thanks each of the sponsoring companies, as well as all of the volunteers who donated their time. -------------------- July 2008: MGS Increases Its Injection Molding Capabilities: Germantown, Wisconsin—MGS Mfg. Group, Inc., a leading provider of engineered manufacturing solutions to the plastics industry, recently invested in two 880 ton Krauss Maffei presses to increase manufacturing capabilities at TecStar Mfg. Company, the division of MGS in Germantown, Wisconsin that handles advanced technology molding. According to Shawn Krenke, Manufacturing Engineer at MGS Mfg. Group, “MGS mechanically and electrically engineered and built all of the automation equipment and end-of-arm tooling for both of the 880 ton manufacturing cells. All end-of-arm tooling is 3D machined Delrin, matching the cavity geometry to act as a nest during the assembly process. All assembly is done while the parts remain on the Wittman robot.” He also states that each system utilizes six-axis LR Mate 200ic Fanuc robots. In addition, MGS Universal Multishot Systems™ Portable Injection Units, rotary platens, hydraulic power units and control panels are integrated into each cell. Both systems are universal to five molds, each producing two parts which place different pin styles and quantities in each part while at the same time ensuring that each pin gets installed properly. This automated quality assurance eliminates the need for having two additional operators at each cell. MGS invested in the 880 ton presses to manufacture a multishot component for Cooper-Standard Automotive, a leading global supplier to the automotive industry. -------------------- June 2008: MGS Mfg. Group Growing to Meet Increasing Demand: Injection molder and mold maker MGS Mfg. Group Inc. is building its presence in blow molding. The company recently added a fourth blow molding machine, and the firm projects 20 percent growth in its blow molding output this year. If business continues as expected, the company may add injection stretch blow molding to its TecStar Manufacturing Co. molding operation at its base in Germantown, Wis. MGS also might bring blow molding to its newly acquired molding facility in Chihuahua, Mexico. That is a lot of growth for a company that did not enter blow molding until four years ago, noted David Sansone, MGS vice president. The trend is being driven by customers who want to consolidate their supply base and simplify product delivery. “Everybody wants to stay lean and minimize their inventory. That means that they have to coordinate deliveries. We can put both bottles and [injection molded] dispensing closures on the same truck,” Sansone said in a June 2 telephone interview. “It’s a single source for them.” MGS’ mold-making experience allows the company to offer an even wider package of products, he said. In addition, the firm’s background in automation helps it compete for business against molders in low-wage regions. It is making one product now that previously was made in China. MGS added a Bekum BM-406D continuous extrusion shuttle blow molding machine at TecStar early this year. The machine can produce containers as large as two gallons. TecStar makes custom containers, medical components and consumer products. The company also has an industrial blow molding machine that it uses for special products, and Sansone said he expects the next addition to be for injection stretch blow molding. MGS had blow molding sales of about $8.5 million in 2007. The new machine and new business should expand its blow molding output by 20 percent through the end of 2008. It expects to add an extrusion shuttle blow molding machine at its TecStar de Mexico plant in Chihuahua by the end of this year, with the possibility for a fifth machine in Germantown by late 2008. To free up space for blow molding in Wisconsin, the company purchased a separate warehouse near its manufacturing campus in Germantown, moved some inventory there, and now has a dedicated blow molding area within the main MGS facilities. “If we look at the fact that we’ve only been in this for about four years, there’s obviously quite a lot happening in this part of the business,” he said. -------------------- June 2008: MGS Does first Chinaplas: MGS exhibited at its first-ever Chinaplas. John Hahn, vice president of engineering, and Richard Kochanski, global account manager, worked a small booth in the U.S. pavilion. Hahn said MGS rotary turntable molds for multishot are used in China by automotive molders, caps and closure makers and other markets. Demand for multishot molding will grow as the Chinese people make more money and seek a higher quality of life, he said. The Germantown, WI based company makes molds and add-on injection units for multishot molding. -------------------- May-2008: MGS Mfg. Group Receives Supplier Excellence Award: The MGS Mfg. Group received the Rubbermaid® Supplier Excellence Award in February of this year. This award was presented for the outstanding service Rubbermaid’s Food Service business unit received from MGS Mfg. Group in 2007. As explained by Yongyi Mason, Senior Sourcing Manager, “Rubbermaid presented the first Supplier Excellence Award in 2006. We wanted to show our appreciation to vendors who exceed our expectations and provide us with superior service.” Rubbermaid selects the winner using four measurements: quality, on-time delivery, productivity, and responsiveness. Mason continues, “MGS delivered on all four measures and did an outstanding job as a business partner.” About Newell Rubbermaid -------------------- May 2008: TecStar de Mexico Now ISO9001:2000 Certified: With the joint effort of the employees at TecStar de Mexico, including team leaders, engineers, production staff, and warehouse personnel, the facility was certified in ISO9001:2000 on April 14, 2008. This certification applies to all types of organizations and helps both product and service oriented organizations achieve standards of quality that are recognized and respected throughout the world. According to Juan Sosa, General Manager of TecStar de Mexico, “The employees worked beyond their responsibilities to ensure the facility complied with the standards set forth by ISO 9000. I am proud of everyone here and pleased to be a part of this facility and of MGS Mfg. Group." -------------------- Apr 2008: MGS Mfg. Group Expands Blow Molding Capabilities with Addition of Fourth Bekum Blow Molding Machine: The MGS Mfg. Group recently placed its fourth Bekum BM-406D fully-automated continuous extrusion shuttle blow molding machine at TecStar Mfg. Company, the division of MGS that handles medium to high volume, advanced technology molding. The adaptable machines allow for the production of an extensive range of products, facilitating the flexibility to produce a variety of containers, from small sizes with high cavitations through large, two-gallon units. These machines offer an array of molding possibilities, including custom containers, medical components, and consumer products. As stated in the 2007 Plastics News Market Data Book, MGS Mfg. Group had blow molding sales of $8.5mil in fiscal 2006. According to David Sansone, Vice President of MGS Mfg. Group, “We’ve had optimal success adding blow molding to our full range of services. Our expertise in blow molding and injection molding provides customers with a single source for both containers and caps/closures. By installing a fourth blow molding machine, we are able to increase our capacities and capabilities to better serve our customers.” Sansone projects that the company’s blow molded output will increase by 20% during the remainder of 2008, and foresees manufacturing productivity to increase even more over the next few years. MGS added blow molding services to its line-up of manufacturing processes eight years ago. Along with its four shuttle blow molding machines, the company also owns an industrial blow molding machine to accommodate special projects. Due to continual growth, TecStar Mfg. Company’s blow molding division recently moved to a larger facility to accommodate their current and impending expansion. In recognition of innovative manufacturing capabilities, TecStar Mfg. Company has received one WorldStar and three AmeriStar awards from the Institute of Packaging Professionals. -------------------- Apr 2008: MGS Mfg. Group Inc. Opens New Facility in Mexico MGS Mfg. Group expanded its manufacturing facilities on January 1st by opening a new location in Chihuahua, Mexico. Named TecStar de Mexico, the facility is an affiliate of TecStar Mfg. Company in Germantown, WI, which handles medium to high volume, advanced technology molding. TecStar de Mexico manufactures products for the electronics, consumer products, and automotive industries. The 75,000+ square feet of manufacturing space houses 30 injection molding machines, ranging from 28 to 770 tons, as well as an on-site tool shop to support production mold preventive maintenance, repairs, engineering changes, and the inspection of incoming transfer molds. There is also an adjacent distribution center which consists of 20,000 square feet of warehouse space. Secondary operations include sonic welding, pad printing, insert machines, and manual assemblies. The site employs 150 people that operate on a 24/7 work shift. This expansion has allowed the company to increase productivity to better serve its customers, both in quantitative and qualitative measures. “TecStar de Mexico provides a cost-effective manufacturing solution”, says David Sansone, Vice President of MGS Mfg. Group. "The strategic location of the facility, combined with the engineering horsepower of MGS, translates to a time-to-market response to our customers serving the North American retail market. By establishing a location in Mexico versus overseas, we are able to act responsively to our customers’ needs and deliver shipments within a few days, therefore allowing customers to keep their inventory levels at a minimum. This also eliminates time lost in oceanic transit and in crowded ports. It has become obvious that our customers appreciate TecStar de Mexico’s accessibility. Meetings and engineering events, like mold sampling and qualification, are no longer day-long travels compared to Asia." MGS is currently increasing capacities and capabilities at TecStar de Mexico through the installation of four additional Negri Bossi presses and has room to grow for future structural expansion. Procedures and systems are being implemented to qualify TecStar de Mexico for ISO 9001:2000 Certification in the second quarter of 2008. --------------------
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