Spring 2011

Sets New
Direction

• 2011
Convention
Wrap
• Mold Builder
of the Year
• EDM of Copper
Beryllium
• Predicting Market
Trends in Plastics

The Official Publication of the American Mold Builders Association

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 Speak Out
I write this quarterly letter with great excitement, with great
anticipation on what’s to come and with a renewed hope for The American Mold Builder
our industry, for our Association and for our companies. Published by the

Some of you may be wondering the source of my excitement.

It’s quite simple: Our company invested time, energy and
money by attending the AMBA convention in Las Vegas this
American Mold Builders Association
past March. The event impacted me tremendously. Going
3601 Algonquin Rd., Suite 304
to the convention reinforced my desire to be the best I can
Rolling Meadows, IL 60008
be, defend my value vs. my overseas competitors, challenge
my traditional ways and aggressively work to improve our p 847.222.9402 • f 847.222.9437
Mike Armbrust info@amba.org • www.amba.org
operations . . . and gave me the tools to do so! AMBA President
I had many “ah-ha” moments during the four-day event. Officers and Board of Directors
My first was listening to Tom Duffey, president and CEO of Plastic Components, President
Inc. (PCI), a custom injection molder in Germantown, WI. Tom is an amazing Mike Armbrust, Mako Mold Corporation
speaker and business leader. He, like many of us, has been battling every day for the
last decade to compete. Just like us, he battles overseas foes; he fights to maintain Vice President
his margins and works to meet daily operational demands. However, his story is Todd Finley, Commercial Tool & Die
uniquely different than most. He has adjusted his business and improved it so much Secretary
that he now sells parts into China. Yes, that’s right; his company is the low-cost Shawn McGrew, Prodigy Mold & Tool
provider. He told a room packed full of moldmaking professionals that he sourced
hundreds of molds overseas in ’07 and ’08 in order to be competitive on producing Treasurer
plastic parts. After saying this, he smiled, paused and then told all of us that he’s Mike Bohning, Creative Blow Mold Tooling
recently changed his sourcing habits. He told of an amazing transformation taking
place in the U.S. moldmaking industry. Of the last 50 tools he’s sourced in over Legal Counsel
the last twelve months, 48 of them have been built by moldmakers in the state of Richard N. Mueller & Associates
Wisconsin. His rationale and in his words, “The U.S. moldmaking industry has
Board of Directors
improved; they’re more competitive; they have invested in their processes; they’ve
become more focused on the customer and they’ve become more innovative.” Andy Baker, Byrne Tool & Die
Hearing this really got me excited. Michael Bohning, Creative Blow Mold Tooling
Robert Earnhardt, Superior Tooling
My second “ah-ha” moment took me by surprise. At the outset of a presentation Dan Glass, Strohwig Industries
focused on using financial information to run your business, new AMBA Executive
Roger Klouda, M.S.I. Mold Builders
Director Troy Nix put me on the spot and asked how financially savvy I rated
myself, based on the presentation topic. I answered quickly by stating I was a six or Justin McPhee, Mold Craft
seven, but by the end of the presentation I downgraded myself into a strong two. I Tim Peterson, Industrial Molds Group
didn’t know what I didn’t know and there are tools we were not utilizing. This was Scott Phipps, United Tool & Mold
an eye-opening experience. It showed me where I could improve my own skills and Steve Rotman, Ameritech Die & Mold
help improve our company. Mike Walter, MET Plastics
Finally, one of my greatest “ah-ha” moments was experiencing the positive impact Wendy Wloszek, Industrial Mold & Machine
of planning. The AMBA Board of Directors has worked for over eight months in AMBA Team
developing a long-term plan for the Association. As a result, the overall convention
Troy Nix, Executive Director
experience was enhanced due to strong content. We learned of innovative networking
Kym Conis, Managing Director
opportunities and of new cost-saving programs from our new management team; and
Susan Daniels, Member Services Coordinator
we experienced an energy and passion from the business leaders not felt for years.
Shannon Merrill, National Chapter Coordinator
Carrying the energy created at the AMBA Annual Convention forward, we’ve
launched a series of plant tour workshops that will start at Mold Craft, Inc. in
Willernie, MN. Sharing best practices and gathering industry metrics is a primary
goal for this Association and the June 14th event is the perfect platform to do just Managing Editor: Kym Conis
that! Mold Craft will share its approach to building a sustainable business model Assistant Editor: Sue Daniels
through design innovation and maximum automation. This is more than a tour; it is Contributing Author: Clare Goldsberry
a professional development workshop where participants will engage in structured Art Director: Cara Pederson
cross-talk with other senior machining professionals on various aspects of running Advertising/Sales: Shannon Merrill
profitable moldmaking companies. (Learn more about this workshop in our Circulation: Shannon Merrill
Association section, page 28) This is just one of many future “ah-ha” opportunities
I encourage you take advantage of! Opinions expressed in this publication may or may
not reflect the views of the Association, and do not
Now that you know the source of my excitement, stay tuned and prepare yourselves necessarily represent official positions or policies of
the Association or its members.
to get involved in the new AMBA! www.amba.org 3
 Contents
Spring 2011

13 16 24

18

Features Departments
6 Market Trends
• Future Markets in Plastics 3 Speak Out
• Mold Manufactures Continue Rising Level of Confidence
15 Industry
12 Focus 28 Association
• AMBA Chapter of the Year
• AMBA Mold Builder of the Year 40 Product
18 Convention 46 Calendar
AMBA Convention Wrap 46 Ad Index
24 Technology
• The Introduction of Laser Ablation for Surface Texturing
• EDM of Copper Beryllium Mold Materials

36 Special Report Visit our Website:

GHS Bringing Changes to OSHA HazCom Standard www.amba.org
39 Inside Track
Maintaining a Culture Shift

4 the american MOLD BUILDER Spring 2011

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 Market Trends

Future Markets in Plastics By Dr. Peter Mooney,

President, Plastics Custom Research Services

I contributed an article to the Winter 2010 issue of Plastics was unique insofar as it was the culmination of several asset
Business in which I reviewed the growth of the major plastics bubbles bursting sequentially – the dot/com crash of 2000, the
industry markets from 2004 through 2009 and then speculated housing collapse of 2005-2006 and the global financial crisis
as to likely developments out to 2014. Normally, there are of 2008-2009. Rebounding from financial crises historically
few second chances in life. However, I’ve been offered takes longer than periodic downturns in the business cycle.
the opportunity to revisit that article, update developments On the other hand, it also was unique insofar as this was a
through 2010 and rub the crystal ball once again. synchronous global recession with few countries and regions
spared its corrosive effects.
The prevailing expectation (hope) one year ago was that
the U.S. economy, having reached the nadir of the “Great Much of the blame can be attributed to the inappropriate and
Recession” in June 2009, would experience either a V-shaped ultimately ineffectual fiscal and monetary policies adopted
or U-shaped recovery. The economy actually did begin to since the onset of the recession. The bailouts of the banks,
recover in the second half of 2009, and this pattern continued insurance companies, car companies and others only served
into 2010. However, the pace of recovery has been so lethargic to preserve the status quo rather than spurring fundamental
that it engendered fears it would ultimately be W-shaped (i.e., reform. The stimulus program of early 2009 preserved other
the dreaded double-dip recession). Today there are many elements of the status quo (e.g., bloated state and local
economists (the author of this piece included) who anticipate government budgets). The mortgage modification program
continuing challenges to get back to the levels of household failed, and it prevented the housing market from reaching a
income, household consumption, capital investment, market-driven bottom from which it could rebound.
employment and unemployment obtained at mid-decade.
The new stimulus program negotiated between the President
First, let’s examine the actual trend of growth of U.S. real and the Republican leadership in December is another effort
GDP over the period covering the recession and subsequent to preserve the status quo (e.g., income tax rates) rather
recovery. We observe in the graph below that the downturn than forcing everyone, regardless of income, to sacrifice in
in this key measure of economic health began in Q1 2008, order to lower the ballooning national debt. The reduction
continued through Q2 2009 and then recovery ensued from in employees’ social security payments will have to be
Q3 2009 up through Q3 2010. Whereas the cumulative loss of financed by borrowing, which will further impede recovery.
output over four quarters was 4.1%, the cumulative recovery The Deficit Commission’s call to address the nation’s broken
over five quarters has only been 3.6%. It will probably take six balance sheet has been put off for yet another day.
quarters (through Q4 2010) for U.S. GDP to fully recover lost
output from the recession. The dilemma we confront as a nation is that we need to reform
many of our basic institutions in order to compete in a rapidly
To put the pace of the current recovery in perspective, the globalizing economy. Yet in the short term, the length and
U.S. economy has experienced only three other episodes of depth of this recent recession, along with the anemic pace
three consecutive quarters of recovery, has made both
of decline in real GDP since consumers and producers
Quarterly % Changes in Real U.S. GDP, 2008-2010 more cautious, more uncertain
WW II. In all three cases,
real GDP recovered more 2008 2009 2010 and more risk-averse. This is
than the lost output over the Q1........-0.2 Q1........-1.2 Q1.........0.9 manifested in many ways –
subsequent three quarters. Q2.........0.1 Q2........-0.2 Q2.........0.4 most clearly in our stubbornly
Q3........-1.0 Q3.........0.4 Q3.........0.6 high unemployment rate
There are several factors Q4........-1.7 Q4.........1.2 Q4.........0.4 since to hire is to take a risk.
contributing to the un- Ben Bernanke, the chairman
folding weak recovery in Source: U.S. Bureau of Economic Analysis; of the Federal Reserve
our economy. On the one 2010 Q4 is author’s estimate Bank, acknowledged this risk-
hand, this latest recession aversion by speculating that
6 the american MOLD BUILDER Spring 2011
 The Trend of Output in Major Markets Served by U.S. Plastics Processors
(indices: 2004 = 100)
Market 2004 2005 2006 2007 2008 2009 2010 2011 2012 2013 2014
Appliances 100 100 101 95 86 75 77 80 85 95 100
Automotive 100 101 98 95 78 61 87 90 94 97 100
Building 100 106 93 69 46 28 30 30 40 50 60
Furniture 100 107 112 115 109 74 73 77 80 85 90
Heavy Trucks 100 117 129 83 72 43 50 76 91 97 94
Marine 100 99 105 97 81 66 70 75 80 85 90
Medical 100 103 106 109 113 116 119 123 127 130 134
Packaging 100 102 104 106 108 110 113 115 117 120 122
RVs 100 104 106 95 64 45 62 67 75 80 90
Other 100 103 106 108 108 105 108 111 113 116 119
Average I 100 104 106 97 86 72 78 84 89 95 99
Average II 100 104 103 99 94 87 91 94 98 103 107
NOTES:
1) Average I is the unweighted average of the various market indices. 2) Average II applies weights to these indices, based on the market shares of plastic product output.

SOURCES:
Appliances: 2004-2010, large appliance shipments from the Association of Home Appliance Manufacturers (2010 based on year-on-year through October); 2011-2014,
PCRS projections
Automotive: 2004-2010, car and light truck production from Wardsauto (2010 based on year-on-year through November); 2011-2014, PCRS projections
Building: 2004-2010, single- and multi-family housing starts from the National Association of Home Builders (2010 based on year-on- year through October); 2011-2014,
PCRS projections
Furniture: 2004-2011, actual and projected sales of office furniture from the Business & Institutional Furniture Manufacturer’s Association International, deflated by the
producer price index for office furniture; 2012-2014, PCRS projections
Heavy Trucks: actual volume of production in 2004-2009 and projections for 2010-2014 from ACT Research
Marine: 2004-2009, new boat sales (units) from the National Marine Manufacturers Association; 2010-2014, PCRS projections
Medical: 2004-2014, assumed to grow 3% per year
Packaging: 2014-2014, assumed to grow 2% per year
Recreational Vehicles: 2004-2011, units produced from the Recreational Vehicle Industry Association; 2012-2014, PCRS projections
Other: 2004-2010, real GDP growth from the U.S. Bureau of Economic Analysis (2010 based on year-to-year through Q3); 2011-2014, PCRS projections

the unemployment rate will not return to 6% or below for
another 4-5 years.
What does all this mean for the U.S. plastics industry?
In the table above I provide an
10 market categories declined by 28% from 2004 to 2009,
and it will take another five years to regain the 2004 level.
The trend of the weighted averages (Average II) presents a
less dire picture; the volume of output declined only 13%
over the past five years, and it will

“
updated and expanded analysis exceed the 2004 level by 2013.
of the past and likely future
trends of growth in volume
The dilemma we confront as a The steady (2% per year) growth
and large weight (33%) of plastics
terms for major markets served nation is that we need to reform in packaging offsets, to some

I have added to this year’s table many of our basic institutions

by plastics industry participants. extent, the continued collapse of
the building industry, which has
a few more markets (e.g., heavy in order to compete in a rapidly

”
the second largest weight (17%).
trucks, recreational vehicles
and packaging) in order to globalizing economy. A few comments are warranted
represent, as comprehensively regarding the likely future trend in
as possible, the entire panoply selected markets:
of plastic processing activities. I also have added 2010 data
and out-year projections supplied by the organizations cited Automotive: Of all the markets included in this year’s
in the table’s sources. tables, automotive is the one bright spot. Compared to the
14% bounce-back forecasted for 2010 last year, the monthly
The trend of the unweighted averages of these market indices production data through November point to a 43% surge. A
(Average I) suggest that the volume of production across these page 9 u
www.amba.org 7
 Market Trends
Moldmakers and Economic Recovery
What will be the likely future economic conditions on which
moldmakers depend for their sustainability and growth? The Fed
has repeatedly alluded to headwinds confronting our economy
as we slowly recover. Namely, these adverse forces affecting
recovery and expansion include household and business
uncertainty, persistent weakness in real estate markets, limited
improvement in labor market conditions, waning effects of fiscal
and monetary stimuli and slow easing of the credit squeeze in the
banking sector.
The Fed believes full recovery to sustainable rates of output
growth, employment and inflation could take 5-6 years. I want
to point to a number of megatrends that will continue to affect
everyone in the U.S. economy, which include the following:
• There’s a long-term evolutionary shift of labor and capital
– first from agriculture, then to manufacturing and finally to
services, accounting for the bulk of output, income and jobs.
• There’s a long-term process of globalization. The United
States has done a poor job adapting to globalization, and
our federal government has also done a poor job protecting
our interests in world trade negotiations.
• We’re experiencing a steady aging of our population. This
puts a greater burden on the generation of workers coming
behind us.
• We’re also experiencing the aging of our capital
infrastructure – our factories, highways, railways, bridges,
electricity transmission lines - all of which are vital to
maintaining U.S. productivity relative to our foreign
competitors. And yet, we are not spending enough to
maintain our existing capital stock and invest in new
capital structures. For the first time in recent U.S. economic
history, the total U.S. capital stock actually declined.
In 2010, our investment in new physical capital wasn’t
sufficient to replace old depreciated physical capital.
• There’s a growing concern for the environment, which
leads to a growing focus on sustainability. This obviously
has enormous implications for the plastics industry.
• There’s the imminent loss of the baby-boomers from our
workforce with all their technical knowledge and skills
and the difficulty we’re experiencing replacing them
with young people with similar skills and work ethic.
Despite all our faults and failings, economists are clear as to
how we can restore the virtuous economic cycle where growth
leads to job creation, which leads to higher household disposable
income, which leads to increased effective demand, which drives
growth. We have to become more productive. We put too much
emphasis on supporting consumer spending in this country. We
8 the american MOLD BUILDER Spring 2011
need to boost the supply side as well. The theme for the 2011
AMBA convention was “Accelerate Your Profitability.” I would
prefer the theme “Accelerate Your Productivity.” Profitability
will inevitably follow. We need to stir what John Maynard
Keynes called the entrepreneurial “animal spirits” – the forces
that spur businesses to look into the unknown and take risks in
order to grow.
Moldmakers have many options for raising their productivity
including:
• If you haven’t done so already you need to apply lean
manufacturing throughout your whole organization.
• You need to maximize energy efficiency
in every aspect of your plants.
• You may need to automate to minimize
your total labor force burden.
• You need to differentiate your company and
your services for a marketing advantage.
• You need to diversify your moldmaking capabilities.
If someone comes to you with a part design that
should be injection molded or blow molded or
extruded, you should have the moldmaking expertise
to take on that job regardless of the process.
• You need to constantly innovate. Your customers
are looking to differentiate their products and
services to rise above the rest. They are wide open
to any innovation that can draw attention to their
brand. You have to assist them in that process.
• Be forward-thinking. You’re obviously concerned
with surviving day-to-day. You’ve been forced to lay
off some of your staff, many of them with valuable
skill sets. Now you’re at the irreducible minimum.
So it’s more important than ever to look ahead to
what some call the “reset economy” of the future.
A few months ago in Las Vegas, the president of Constar
International, a major bottle blow molder, made a presentation
to The Packaging Conference. He made comments which I
found really profound. He stated that like everyone else he is
determined to make his company leaner. He added that “at the
end of the day the only way you can be sustainable is to be
technically relevant.” Size matters less than being technically
relevant. This applies to small companies like mine and big
companies like yours. Maintaining the status quo won’t cut it.
You must be willing to innovate, take risks and keep up-to-date
with the latest technologies in order to be technically relevant to
your customers. You won’t survive as a me-too moldmaker. 
t page 7
return to the 2004 volume of automotive production seems
within reach by 2014.

Building and Construction: It’s impossible to underestimate

the collateral damage to several major markets for plastics
(e.g., appliances, furniture) from the continuing collapse of
the housing market, a segment of which (houses financed
with sub-prime mortgages) contributed mightily to the Great
Recession. House repossessions so far in 2010 have tallied
1.3 million, up from 900,000 in 2009, and the numbers are
expected to go up again in 2011. Mortgage loan modifications
have failed to arrest this wrenching economic and social
calamity. Loans 60 or more days past due as a percentage of
all mortgages will fall slightly to 5% in 2010 from 6.2% in
2009, yet both numbers are multiples of the normal 1.5-2.0%
range. These trends push up the total housing inventory. As
the supply of housing increases while demand stagnates due
to continuing high unemployment levels, house pricing has
to decline another 5-10% to clear the market. And to make
matters worse, the yield on the 10-year Treasury bond on which
mortgage rates are based has been rising, contrary to the Fed’s
intentions with its latest quantitative easing program. So, it
will be 2012 before any rebound in housing starts and 2015-
2017 before residential building and construction regains the
2004 level. Millstar Tools take the HEAT —
Increase Mold-Making Production.
Heavy trucks: The market for heavy (Class 8) trucks is
With Millstar cutter strategies and high-speed machining solu-
highly influenced by the timing of implementation of EPA’s tions mold makers produce more finished molds and dies in less
increasingly stringent standards related to greenhouse gas time.
emissions from the engines in these vehicles. The standards Millstar cutting tools provide mold makers:
were raised in 2002 and 2007, triggering pronounced
• Decrease lead times with unmatched process and
pre-buying of trucks in previous years. Standards were raised product support
once again in 2010, yet the recession dampened the extent of
• Industry leading accuracy for true contouring results
pre-buying. The next set of standards will come into force in
• Advanced tool geometry and coatings for simultane-
2014, which explains the expected pause in heavy truck sales
ous chip and heat removal
that year.
We’re ready to take the heat! Contact Millstar today.

Medical: Irrespective of the hotly debated constitutionality of

Call 1-877-645-5792
the Affordable Care Act, in an aging society the demand for
(1-877-MILLSTAR)
medical disposable and durable products will rise inexorably.
In the absence of official data, we assume a constant 3% Don’t be fooled by imitations—look for
increase in the volume of production of plastic medical/ the Cole Crown on every insert.

pharmaceutical goods from 2004 through 2014.

Packaging: This is another market which defies simple

measurement of trends since it embraces bags, bottles, caps Millstar World Headquarters
and closures, film, pouches, etc. We assume that recent past 30200 Ryan Road • Warren, MI 48092 U.S.A.
and likely future volume growth approximates twice the long- Tel: (586) 573-9450 • Fax: (586) 573-9451
Email: info@millstar.com • www.millstar.com
term growth of the U.S. population (i.e., 2%).

Recreational vehicles: Recovery of the recreational vehicle

industry hinges critically on trends in household income and
page 10 u
www.amba.org 9
 Market Trends
t page 9
gasoline pricing, and the latter correlates in turn with crude
oil pricing. As a result of the Great Recession, oil pricing
actually averaged only $62/barrel in 2009, but this positive
for RV sales was overwhelmed by the erosion of household
wealth. The U.S. Department of Energy expects crude oil
to cost $86/barrel on average in 2011. Gasoline pricing is
expected to average $3.00/gallon in 2011, up 8% from $2.77/
gallon in 2010.
(23% in inflation-adjusted terms) to regain the pre-recession
peak of $66 trillion. Economists believe it will take at least
the middle of the decade for Americans to regain all their lost
wealth.
In the end, any forecast for growth of the U.S. economy must be
predicated on where such growth will emanate. Consumption
accounts for 70% of GDP. The stimulus package of 2008
failed to boost consumption, and there

“
is little prospect that the December 2010
compromise crafted by President Obama
Unemployment and jobs were the two most and the Republican leadership will fare
important issues facing the country, and yet the any better. Government spending at every
level – federal, state and local – simply has
focus of the 2011 Congress will be on repealing to be reduced. There is a glut of productive
and replacing the enacted healthcare reform and in plants, office buildings, retail outlets,
capacity in the country, so investment

ensuring that no one’s marginal tax rate rises.

”
et al. will languish. The depreciation of
the dollar, the supposedly unintentional
side-effect of the latest Fed’s quantitative
easing program, may spur exports but it
The trend of crude oil pricing obviously impacts forcefully is provoking competitive devaluations among our trading
on the cost-competitiveness of resins. There are actually partners.
encouraging signs relative to future oil pricing. There is a lot
more oil lying around; in light of recent discoveries in Brazil Some business analysts would argue that there is a rosy
and other countries, estimates of global oil reserves have been scenario ahead for plastics industry companies serving the
adjusted upwards. At the same time, despite the voracious major manufacturing industries. The Institute for Supply
Chinese appetite for oil (and every other commodity), global Management (ISM) reports that manufacturing output has
oil demand has moderated as a result of increased energy grown for 16 consecutive months, and it projects continued
efficiency. The International Energy Agency once projected recovery through 2011. Companies in the manufacturing
that the world would be consuming 94 million barrels a day by sector are operating at 80.2% of capacity versus 72.8% in
2011. Now they don’t see that level being reached until 2020. 2009. Exports are growing as the value of the U.S. dollar
weakens.
Conclusion
As the year 2010 came to a close, over half of Americans in a And yet, the picture remains troubling for long-term future
Bloomberg poll conducted in early December said they were growth prospects in manufacturing, including the plastics
worse off than they were in 2008, and two-thirds believed the industry. 2009 was the first year in recorded U.S. economic
country was headed in the wrong direction. Unemployment history that the capital stock actually declined. Claiming
and jobs were the two most important issues facing the continuing uncertainty companies accumulated huge cash
country, and yet the focus of the 2011 Congress will be on hoards. Debt was reduced, and yet capital investment
repealing and replacing the enacted healthcare reform and languished and work-forces were cut. The only V-shaped
ensuring that no one’s marginal tax rate rises. The federal recovery in evidence is in corporate profitability. This
government can afford to put off the inevitable; state and local conservative posture must be abandoned if we are to remain
governments, faced with looming budget gaps, cannot. Thus competitive with our trading partners in both developed and
the reduction of public sector jobs will offset any potential job developing countries. 
creation in the private sector in 2011. Many economists and
business analysts foresee unemployment remaining mired in Dr. Peter J. Mooney is president of Plastics Custom Research
the 9-10% range out to 2012. Services of Advance, NC and one of the plastics industry’s
foremost economic research experts on evolving domestic and
U.S. net worth, which plummeted to $49 trillion in the first global plastics industry market opportunities. Visit the Plastics
quarter of 2009, recovered to $55 trillion by the third quarter Custom Research Services website at www.plasres.com.
of 2010. However, it would have to recover another 20%

10 the american MOLD BUILDER Spring 2011

 Mold Manufacturers
Continue Rising Level of Confidence
AMBA Spring 2011 Business Forecast Survey Results
Results of the AMBA Spring 2011 quarterly survey of members say backlog is “Up” significantly compared to 33% in the Winter
reveals that business continues to grow, fueling optimism in the The AMBA Business Forecast Survey was developed to provide AMBA members with information
survey.
on the Backlog
current business is the
conditions and“Same” for
a projection of the26%
upcoming (down
months.from 49%);
The Spring 2011 and
economy. Survey respondents reported that current business Survey “Down”
resulted afor 30%
response rate(a 3%from
of 30% dropAMBA from theBusiness
members. Winter survey).
remains "Good" At the
for 54% of the respondents, and for 20% of the respondents it is "Excellent."
conditions are “Excellent” – rising five full percentage points to recent Amerimold trade show in Rosemont, IL, an informal
20% from the 15% reported in the Winter 2011 survey. Current survey of the moldmakers there revealed
AMBA Members Current Business Projection of that most
Business Over theare
Next 3seeing
business conditions are “Good” for 54% of respondents, down a significant backlog that
Conditions
will carry them through
Months
the summer. Increase
Excellent 52% Substantially
two percentage points from the AMBAWinter
Spring 2011
2011survey.
Business “Fair”
Forecast Survey Results54%
Good Increase
business conditions exist for 22% of the respondents compared Profits
The AMBA Business Forecast Survey was developed to provide AMBAinmembersthe Spring withsurvey
information
Fair
are “Up” for 30% of the respondents Moderately

to 20% of the respondents

on the in the Winter
current business survey.
conditions and a Those reporting
projection – a nice
of the upcoming uptick
months. Thefrom
Spring 24%
Poor2011 in the Winter 8%
survey. Profits are Samethe
Remain the

“Poor” business
Survey conditions droppedrate
resulted a response two percentage
of 30% from AMBApoints to “Same”
members.
20%
0% for
Business 53%
remains 22%and
"Good" “Down”
Bad
for 17% of the
0% respondents
1% 39%
(a 20%
Decrease
Moderately
4% from 6%. For of
for 54% thethe
fifth consecutive
respondents, andsurvey,
for 20% no onerespondents
of the reported it is drop
"Excellent."
4%
from the last quarter). Decrease

“Bad” business conditions.

Substantially

Current Level of Business in Last 3 Months

AMBA Members Current Business Projection
60%
of Business Over the Next 3
Quoting
Conditions Months
50% Increase
Shipments
Excellent 52% Substantially
54% 40%
Backlog
Good 30%
Increase
Moderately
Profits
20%
Fair
Remain the
10% Employment
Same
Poor 8%
20% 0%
39%
1%
Up Decrease
Same Down
0% 22% Bad 0% Moderately
4%
Employment levels alsoDecrease are confirming that responding
Current Number Plant Employees
Current Work-Week Hours
50

Second quarter 2011 projections for business over the next three companies are much busierSubstantially
50
then in the Winter 2011 quarter, with
40
40

months reveals the majority of respondents expect their businesses

in Lastemployment
3 Months 48once again trending “Up” for 36% of Spring survey

Plant Employees
Current Level of Business
Work Hours

30 30
47
to “Increase Substantially” (8% compared to 6% in the Winter respondents, compared to 30% from last quarter; 20
25
remain the 20

survey) or “Increase
60%
Moderately” (52% – a full 10% higher than “Same” for 56%; and are “Down” for only 8% of the respondents
Quoting
10
5
10

ring 2011 theBusiness

Winter survey).
50% Respondents expecting business to “Remain
Forecast Survey Results – the same as the Winter survey. This continues on a significant
Shipments
0 0

the Same” came40% in at 39%, a negligible drop from last quarter – “positive” trend for the last four quarters.
Average Shop Employees Average Design & Engineering Employees
Average Shop Hours Average Design & Engineering Hours

urvey was developedthat

indicating to provide
business AMBA members
is fairly withRespondents
steady. information expecting Backlog
s and a projection of the upcoming
30% months. The Spring 2011
business to “Decrease Moderately” dropped significantly once Shop Has hours remain steady
your company hired any at 48 hours; but for design and
of 30% from AMBA members. Business remains "Good" Profits
again four percentage
20% points,
for 20% of the respondents it is "Excellent." down from 11% in the Winter engineering employees,
machinists/moldmakers in the pasthours
3 are down by one to 47 hours (48
Has it been difficult to find skilled
machinists/moldmakers?
months?
survey. None expect10% business to “Decrease Substantially.” hours in the Winter 2011 survey). The current number of shop
Employment
18%

0%
employees jumped46%to 25 compared to 22 in the Winter survey;
ness Projection of Business Over the Next 3
Up
Months
Same but design and engineering
Down Yes employees remain at five, the same Yes

Excellent 52%
Increase
Substantially
as the previous two surveys.
Current Number Plant Employees
Current Work-Week Hours No No

Increase 50
Good 50
Moderately Respondents
54%
indicate they are hiring shop employees, 82%
with 46%
40
Fair 40
reporting they have hired an average of two employees in the
Plant Employees

Remain the
Same past three months. Finding skilled employees is becoming a
Work Hours

30 30
Poor 8% 48 47
Bad 20 0%
1% 39% Decrease 20 bigger problem for mold manufacturers, with 82% reporting that
Moderately 25
10
it has been “difficult 5 to find skilled machinists/moldmakers.”
10 Decrease
Substantially
When asked to explain this shortage, 77% responded that “many
0 0
have left the trade” as the primary reason; 35% cited “other
rent Level of Business in Last 3 Months Average Shop Employees Average Design & Engineering Employees
When asked to compare
Average current
Shop Hours business
Average Designlevels with
& Engineering Hoursthe previous
shops hiring again – more competition for the skilled people”
quarter, responses indicate some movement Quoting in a positive still available; and 88% said a lack of people “entering the trade
direction. Quoting activity ticked “Up” by one percentage makes it tough to find young people to train.”
point to 38%; 49% responded the “Same;”
Has your company and 14% responded
Shipments
hired any
“Down” (a significant drop from last quarter’s
machinists/moldmakers in the past 22%).
3 Has it been difficult
Responding to tothe
find questions
skilled about hiring, one respondent
Backlog
months? machinists/moldmakers?
commented that “good people are never easy to find.” Another
Shipments are “Up” for 37% of the respondents, 46%
Profits compared to remarked 18% that “Those who are available possess a lower quality
33% in the previous quarter’s survey; stayedEmployment the “Same” for 49% of experience and skills.” Finally, another respondent said,
of respondents (same as the Winter survey); and were “Down” “Many seasoned people cannot make the transition to our fast
Yes
for 14% of the respondents
Same Down
(compared to 18% last quarter). 44% pace and use of technology.”Yes 
www.amba.org 11
No No
Hours Current Number Plant Employees
 Focus
AMBA CHAPTER OF THE YEAR
CHICAGO

AMBA Chicago chapter members accept the 2011 Chapter of the Year award at AMBA’s National Convention in Las
Vegas. (l. to r. Mike Armbrust, Mako Mold; Phil Denemark, Mako Mold; Olav Bradley, PM Mold; Wayne Sikorcin,
Craftsman Tool; Tim Peterson, Industrial Molds Group; Alan Petrucci, B A Die Mold, Alan Szymanski, Do-Rite Die,
David Plocinski, Tri-Par Die & Mold and Mike Walter, MET Plastics.) (photo ©2011 Todd Schuett, Creative Technology Corp.)

The Chicago chapter was named the Chapter of the Year at the
recent 2011 Annual Convention in Las Vegas. The Chicago
chapter was the original chapter of the AMBA and currently
has 38 member companies. The chapter received a check from
Progressive Components for $5,000 to use in its efforts to
promote moldmaking and the mold manufacturing industry in
its area.
The Chicago chapter received this award for its tireless efforts
to promote the trade and encourage young people to enter the
industry. “We understand the workforce is getting older and
we need young people to enter the trade if we are to keep this
industry strong for the next generations,” said Wayne Sikorcin,
owner of Craftsman Tool & Mold Inc. and president of the
Chicago chapter.
Educating its members and getting them involved with
government affairs is a big focus of the Chicago chapter. “One
of the chapter’s goals is to get its members involved with their
legislators, both state and federal, and to have them invite their
legislators to visit their plants to see first-hand what mold
manufacturing is all about and understand how vital it is to
U.S. manufacturing,” said Karen Norville, the Chicago chapter
coordinator. “Several of our chapter members have done that.
One member even got more work from it because the legislator
knew someone who knew a company that needed a mold, so
it’s been successful.”
The Chicago chapter had a large number of members attend
the AMBA Fall Conference in Washington, D.C. As a result of
these efforts, a few local legislators have attended the Chicago
chapter meetings, such as Illinois State Representative Michael
G. Connelly (R) and Congressional Representative Donald A.
Manzullo (R-IL). “Both of these men are pro-manufacturing,
and we want them to know that what they’re doing for us means
a lot to us and we’re behind them,” said Sikorcin.
The Chicago chapter just awarded its first “Mold Your Career”
award. “We wanted to give a scholarship to someone working in
the industry for at least one year at a chapter member company
and help those who have chosen moldmaking as a career,” said
Sikorcin. DGI Supply, a tool seller, donated one-third of the
$1,000 gift certificate to purchase tools at DGI. Michael Gach of
Dynasty Mold Builders was the recipient. “The industry needs
younger workers and we’re hoping this might motivate people
to enter the trade,” he added.
Sikorcin said that the chapter will choose how to distribute the
$5,000 scholarship award at its next chapter meeting. “We will
have five learning institutions named and the chapter members
will decide where to donate the money,” said Sikorcin. “I want
to sincerely thank Progressive Components, who is constantly
backing us in our efforts here in Chicago.”

12 the american MOLD BUILDER Spring 2011

 AMBA MOLD BUILDER OF THE YEAR

W hen Alan Petrucci started

PETRUCCI
ALAN
his own business in 1968,
B A Die Mold Inc., Rolling
Meadows, IL, he never dreamed
that he would become one of the
mold manufacturing industry’s
most honored businessmen. On
March 4, Alan Petrucci was named
the American Mold Builders
Association 2011 Mold Builder of
the Year. The award was presented
by Mike Armbrust, president of
the AMBA. In addition to the
award, Alan received a $5,000
scholarship award donated by
Progressive Components. He
will select an industry-related
Mike Armbrust, AMBA president, presenting the Mold Builder of the Year
educational institution to which award to 2011 winner, Alan Petrucci of B A Die Mold. (photo ©2011 Todd
he will donate the money. Schuett, Creative Technology Corp.)

Alan Petrucci has spent more than 53 years in the moldbuilding
industry. His career began as a teenager working for his father,
Henry Petrucci, who owned Mirro-Brite, a mold polishing
company. Alan began his apprenticeship as a moldmaker after
high school at age 17.
Alan has been a member of the AMBA for over 38 years and was
instrumental in the founding of the organization with other local
Chicago-area mold companies in 1973. B A Die Mold would
have been one of the ‘official’ charter companies of AMBA if
Alan had not had to work that night to deliver a mold on time.
Alan has been active in the organization since day one,
volunteering his time to teach at College of DuPage via
the AMBA’s early apprenticeship program and serving on
apprenticeship committees. He also served on the Lyons
Township High School Board for Vocational Training where
he not only promoted moldmaking as a viable career path, but
also spoke on career days to the students and advised the high
school about how to structure its machinist and metalworking
programs. He donated his time and resources wherever possible
to ensure that all apprentices got a good start in the industry,
and he has employed and educated numerous apprentices at B
A Die Mold over the years – many of whom now own their
own companies as a result. To this day, he attends nearly every
Chicago chapter meeting and has even hosted many meetings in
his own company board room.
Alan has served the AMBA in many capacities over the years
including:
• National AMBA board member 1991 – 2000
• Chicago chapter president 1995 – 1997
• Chicago chapter board member 1997 – 2001
• Chicago chapter board of director – present
Alan was a founding member of the Save American
Manufacturing (SAM) USA organization, which went national
and held a two-day conference, and has never ceased in his
endeavors to see U.S. manufacturing regain a strong foothold
in the global marketplace. He reminds everyone to “Read the
label, Mabel” and buy American-made products, and has met
with and contacted many Illinois and federal elected officials to
make them aware of issues important to our industry.
Most recently, B A Die Mold developed a system that offers
precision positioning of virtually unlimited threads on any given
part. The Programmable Electric Rotating Core (PERC) can be
adapted to both traditional and hydraulic molding machines.
page 14 u
www.amba.org 13
 Focus
t page 13

PERC was officially patented in 2010 and customers who have

utilized the system have only five star reviews for it. In an article
published about B A, Alan said, “I consider something like the
PERC System growth. It’s not how many people you have in the
company; it’s what you do to further the industry.”

“While listening to Mike Armbrust (president of the AMBA)

introduce the Mold Builder of the Year award winner, I was
trying to guess whether or not I knew the person since the years
mentioned seemed to match my own,” said Petrucci afterwards.
“When it dawned on me it was me he was introducing, I was
totally dumbstruck. My daughter, Cyndi, had to give me a shove
to get me started up to the podium. I was so overwhelmed with
emotion realizing that I had been selected out of all the countless
other fine shop owners who deserved this, that I couldn’t find
words to express my gratitude. I did manage to blurt out, ‘I love
the trade!’ All I could think of was that I’ve been selected to join Glenn Starkey, Progressive Components, presenting Alan Petrucci of
a very special group of my peers. Thank you!”  B A Die Mold the 2011 Mold Builder of the Year with a $5,000 Scholarship prize.
(photo ©2011 Todd Schuett, Creative Technology Corp.)

14 the american MOLD BUILDER Spring 2011

 Industry
In Memoriam – Harold Steele, H.S. Die
H.S. Die Founder and President Harold Steele passed away February 24, 2011.
Harold and H.S. Die supported the AMBA for more than 30 years and Harold’s
passing is a great loss to the community, to H.S. Die and to the AMBA. The Steele
family and H.S. Die employees have expressed their gratitude for the calls, emails
and cards expressing
UltraPolishing AMBA Ad concerns
2009.pdf for Harold
10/6/09 3:02:05 and
PM his family over the past year. The
company was closed on February 28 in honor of its late president.

Eagle Tool Receives Small Business Minco Group Adds 1,100-Ton Press
Certification Minco Group, Dayton, OH, is installing its largest injection
Eagle Tool Company, Dyersville, Iowa, a mold manufacturer molding press, at one of its All Service Plastic Molding Inc.
specializing in custom injection molds for plastics and die cast plants in Ohio, to meet increased demand for its parts. The
dies, announced that it has received a “Targeted Small Business” 1,100-ton Ube press, set to go into operation by the end of May,
certification from the state of Iowa. The announcement was will be both the largest press in Minco’s 54-press fleet and the
made by Georgia Brown, president of Eagle Tool. largest all-electric for the company, said Gary Deaton, manager
of marketing and manufacturing for Dayton, Ohio-based Minco.
The Targeted Small Business Assistance (TSB) Program The company has been happy with smaller all-electric presses,
supports the creation and expansion of small businesses that are and decided to stick with electric when it needed a larger press
certified as TSBs. To qualify for the program, a business must to produce lighting parts for the auto industry. Minco’s ASPM
have annual gross sales of less than $4 million and be at least 51% operation has molding in Dayton and in nearby Fairborn, Ohio.
owned, operated and actively managed by women, minorities or page 16 u
persons with disabilities. In addition, the business must be a for
a profit business headquartered in Iowa. “The federal and state
governments have established goals to expand opportunities for
TSBs. As a company with over twenty-five years of providing
high-quality service, our existing and potential clients with
publicly funded contracts can trust that we not only satisfy
these goals, but that we also can continue to provide the leading
industry tooling we’ve come to be known for,” said Brown. “This
opens up new opportunities for the company; opportunities that
we’ll use to re-invest in our employees, our community and the
state’s industrial base.” C

Maximum Mold Recognized as

M

“Michigan 50 Companies to Watch”

Y

Maximum Mold, Benton Harbor, MI, has been recognized as

CM

one of the 2011 “Michigan 50 Companies to Watch,” an awards

MY

program sponsored by the Edward Lowe Foundation and

CY

presented by Michigan Celebrates Small Business.

CMY

Maximum Mold specializes in die casts, plastic injection molds,

contract machining and fixtures. To stand out in a competitive
market, Maximum Mold continually invests in faster equipment
and new technology, including 3D modeling capabilities and
reverse engineering. President Dave LaGrow states, “The tool
and die industry is still alive and well in our community and
state and I am proud to be in Michigan. We strive to provide our
customers with the best services and tools in order to meet and
exceed the needs of their customers with on-time deliver.”

www.amba.org 15
 Industry
AMBA Member Starts ‘iPad
for Wounded Warriors’ Campaign
t page 15
When Tim Bartz, vice president of operations for Mold Craft
Inc. Willernie, MN, heard about the work that Will Byers, a
veteran of the Iraq war, does with members of the 3/5th Dark
Horse Battalion who have been wounded in Afghanistan, he
knew he had to help out somehow.
Bartz heard about Will Byers’ efforts from Will’s father,
Bob Byers of Byers and Associates, a company that provides
consulting services to mold manufacturers. “My son is a Marine,
but just before he was set to deploy to Afghanistan he was
diagnosed with cancer,” explained Byers. “My son stayed behind
at Camp Pendleton to have surgery, and while he was recovering
and receiving treatment, he worked in the office doing reporting
for the Battalion’s casualties. He knows all the people personally
in his Battalion, and many of them came back to the Balboa
Naval Hospital in San Diego for treatment.”
Byers’ son began making regular trips to the hospital to visit the
Wounded Warriors Wing where his comrades were recuperating
from wounds received as the result of IEDs. “These guys in the
3/5th are really neat guys,” noted Bob Byers, who has visited
the Marines with his son. “I was awed by their attitude and
their spirit.”
When Bartz received an email sent to 23 people from Bob Byers
explaining about his son and the wounded from the 3/5th Dark
Horse Battalion, Bartz got an idea that he and other members of
the American Mold Builders Association could do something
for these wounded Marines. Bartz decided that Mold Craft
would make a donation towards helping purchase iPads for each
wounded soldier. He replied to all 23 people on Byers’ email
and challenged them to do the same. The iPads would allow
the wounded to keep in contact with family and friends while
they’re convalescing.
“We had hoped to raise a thousand dollars or so, but over the
course of about a month, we raised $9,400. Some donors met
Mold Craft’s donation, but many gave much more,” said Bartz.
“The money was used to purchase iPads, which were presented
to these soldiers personally by AMBA members.” The iPads
went to Marine amputees at both California’s Balboa Hospital
and Walter Reed Hospital in D.C. In addition, $500 was also
donated to the Marine Ball.
Bob Byers added, “The iPads are a great idea, and allows them
to do a lot of social networking on the internet while they’re
recuperating in the hospital. I’m very proud of my son and his
big heart, but it was Tim and the AMBA members that did the
rest. There’s no more patriotic group than the American Mold
Builders Association.”
16 the american MOLD BUILDER Spring 2011
AMBA members
visit Walter Reed
Hospital in D.C.,
to present iPads
to recuperating
wounded Marines.
Tim Bartz traveled from Minnesota to California’s Balboa
Hospital to personally deliver half of the purchased iPads. In
addition, Steve Rotman of Ameritech Tool & Die, Robbie
Earnhardt of Superior Tooling and Scott Phipps of United Tool
& Mold traveled from both North and South Carolina to Walter
Reed Hospital in D.C. to deliver the remaining iPads. Rotman
said of his visit with the wounded soldiers, “We had an awesome
visit and will never be the same. These young men have so much
courage and such great attitudes it was unbelievable. It was
awe-inspiring to say the least.”
Tim Bartz, Mold
Craft, presents
iPads purchased
with funds raised
by AMBA mem-
bers at Califor-
nia’s Balboa
Naval Hospital.
After the visit Earnhardt said, “Steve, Scott, and I made the
very emotional and eye-opening trip to Walter Reed Hospital in
Washington, DC. This was an honor and an experience that will
stay with me for the rest of my life. It was heart-breaking to see
these guys with their injuries, and all I could think of was how
young they were and the sacrifice that they had made so that all
Americans can enjoy our freedom. These guys were all in good
spirits and had very good support. I only wish that all Americans
could understand what these young men and women are going
through for all of us. I can’t wait until our next trip, and I hope
we can all come together within the AMBA to make the next trip
100 times bigger and better for these guys. If we can enhance
the life of even one of these brave men or women then it’s all
worth it.”
AMBA Members
Win 2011
Leadtime
Leaders Awards
Large Shop Winner
United Tool & Mold, Inc.
With a niche specialty in mold repair, three plants in the south-
eastern part of the U. S. and the acquisition of mold manufac-
turer JungwooUSA has resulted in United Tool & Mold, Inc.
(UTM), Easley, SC thriving over the past several years. UTM
has 70 employees spread throughout its three locations, primarily
serving the automotive, lawn and garden, appliances, large truck
and power tools markets. In addition to mold repair, UTM also
builds plastic injection, blow and compression molds, as well as
performing engineering changes, engineering services, service
on-site, laser welding and in-house texturing.
Small Shop Winner
Mold-Tech, Inc.
Since 1978, Mold-Tech, Inc. Albertville, MN, has zeroed in on
manufacturing specialty molds ― such as prototype, development,
bridge, multi-cavity, hot runner, auto unscrewing, insert, in-mold
decorating, micro, metal injection, silicone, shuttle, multi-shot
and stack with an average lead time of six weeks. Strict attention
to detail while producing these close-tolerance, precision injection
molds has led to success for the company, which primarily
serves the medical, electronics, consumer, automotive and
telecommunications markets.
Honorable Mentions:
Large Shop Honorable Mention
MSI Mold Builders
MSI Mold Builder, Cedar Rapids, IA, counts on a team-driven
approach ― along with lean manufacturing principles to reduce
waste ― to provide high quality, low maintenance and efficient
plastic molds in the shortest possible timeframes. The company
focuses on the design, build, repair and part design of prototype
molds, as well as the design and build of injection, gas assist,
external gas, structural foam and structural web processes.
Customer demand for a reduction in mold delivery time drove
MSI’s re-definition of its manufacturing process through the
use of an incremental approval system that begins with mold
concept and continues through final design.
Small Shop Honorable Mention
JM Mold South
JM Mold South, Easley, SC, bills itself as a combination
of traditional strengths of full-service metalworking and
conservative business management with continuous improvement
in processes, cutting-edge technologies and established relations
with Asian manufacturing partners. Services include mold and
die design, manufacturing and full-service tooling capabilities in
plastics and metal forming to OEMs and suppliers in industries
such as aerospace, appliances, automotive, consumer products,
electronics, lawn and garden, medical technologies, power
generation, power tools and returnable packaging. 
For more information on the Leadtime Leader Awards, contact
Christina Fuges, editorial director, MoldMaking Technology maga-
zine, cfuges@gardnerweb.com, 800. 579.8809, Fax: 513.527.8801
Optimism Prevails at
Amerimold 2011
amerimold– an event for tool and moldmaking, injection
molding and rapid product development – closed on April 14,
2011, at the Donald E. Stephens Center in Rosemont, IL. The
two-day tradeshow, technical conference and networking event
featured more than 2,000 registrants representing 42 states and
25 countries.
The amerimold exhibit hall included more than 100 exhibitors
displaying technologies ranging from 5-axis machining centers
to 3D printers; simulation software to cutting tools; mold
components to materials. The show enjoyed increased exhibit
hall attendance in 2011, with the average amerimold exhibitor
collecting more than 55 well-qualified leads. There were multiple
reports of show floor equipment sales.
“After an ambitious debut in 2010, we set out to reposition
amerimold much in the spirit of its predecessor, the MoldMaking
Expo. In doing so, we focused on two things – providing
great technical content and connecting buyers and sellers of
manufacturing technology. In reviewing this show’s performance
and speaking with exhibitors, we are confident that we delivered
on both accounts and have positioned the event for great success,
moving forward,” said Executive Director, Allison Miller. This
year’s technical conference consisted of two technology tracks –
mold manufacturing and additive manufacturing.
The conferences featured more than 115 registered attendees
and more than 50 industry experts who explored technologies
ranging from automated tooling to direct metal laser sintering.
Complementing the traditional technical presentation format,
interactive roundtables and panel presentations were introduced
this year with lively discussions on management strategies,
customer satisfaction and business development.
In closing the successful 2011 campaign, show management
announced that amerimold 2012 will be held June 13-14 at Novi,
MI’s, Suburban Collection Showplace. 
www.amba.org 17
 Convention
AMBA Conv
T
he American Mold Builder Association hit the mark
with a strong turnout at its 2011 Convention in March
at the Red Rock Resort in Las Vegas. Fueled by the
convention’s theme: Accelerate Your Profitability, attendees
and guests rallied for three value-packed days of educational
programming, best practices benchmarking and networking
opportunities amidst the excitement and high energy of the
association’s new direction. The convention’s strong line-up
of programming provided attendees with the perfect venue to
discover new technologies (both in general sessions and at the
supplier trade fair), explore industry trends and evaluate current
business practices.
General Sessions
Keynote Speaker - “Defending Your Price”
Stephen Rose, Practice Lead Automotive & Commercial,
with Kotler Marketing Group
Many mold manufacturers get caught in the “low price” trap and
are forced into defending their price without data to back up why
their price is the best “value” for the money. So, if price isn’t the
best way to compete and capture new business, just how can mold
manufacturers get the price they need to get to be profitable?
Stephen Rose told attendees what it takes to defend their price
to an OEM community that is increasingly price conscious.
“Defending your price isn’t difficult if you can quantify your
value; quantify your benefits to the OEM customer,” he said.
Laurie Harbour, Harbor Results, Inc., convention presenter
18 the american MOLD BUILDER Spring 2011
Most mold manufacturers base their pricing on their costs, Rose
pointed out. That model needs to change to one in which the
supplier understands its value, and what their offering is worth it
to the OEM customer. Then, offer more value and focus less on
being the low price bidder or on matching the competitor’s bid.
The reality is that OEMs don’t care about the supplier’s costs;
they are only interested in the value that the supplier provides.
Rose stated, “The bottom line to getting your price is, to
understand the value, sell the value and then audit the value.”
“Domestic and Foreign Economic Forces
Impacting the Mold Industry”
Dr. Peter Mooney, Plastics Custom Research Services
Dr. Peter Mooney presented well-researched information on
how domestic and foreign economic forces are impacting the
mold industry. While moldmakers are generally very busy – and
2010 was a better year than many expected – this has been the
“weakest recovery we’ve had” of any of the recessions. “The
downturn has been longer and deeper,” he said. “And it was a
recession of our own doing: Lack of enforcement of lending
rules on rogue banks.”
Dr. Mooney suggested that there are two important ways mold
manufacturers can be more successful. First, become more
productive. “Accelerate your productivity and your profitability
will follow,” he said.
Secondly, be sustainable. “The only way to be sustainable is to
be technologically relevant to your customers,” he said. “You
won’t survive as a me-too moldmaker.”
“Profit Mastery: Measuring and Managing
Financial Performance”
Steve Lefever, Chairman, Business Resource Services
Profits and cash flow are key drivers in a business. “You must be
able to measure your business performance,” Steve Lefever, told
convention attendees. The main message for the past three years
has been: Manage better! He reminded attendees of two primary
rules: “Borrowing is a privilege, not a right;” and “Know your
numbers or stay away” from lenders.

ention Wrap
“None of us can change the economy as individuals, but we can
change our businesses by managing better,” Lefever said, and he
provided Seven Steps to Business Success:
1. Plan properly before startup
2. Monitor your financial position – i.e., financial intelligence
3. Understand the relationship between price, volume and costs
4. Manage cash flow
5. Manage growth – don’t “grow broke”
6. Borrow properly – “most borrow too little money – get it
right the first time”
7. Plan for transition
“However,” said Lefever, “if you don’t do the first six steps
right, you won’t have to worry about number seven.”
“Reap Immediate Return on Your
Convention Investment”
Laurie Harbour, President, Harbour Results
During her presentation, Laurie Harbour (an expert in operational
excellence, financial advisory and strategic development)
emphasized key profit strategies learned at the AMBA conference
and guided attendees through a simple, tactical plan on how
to reap immediate return from their conference investment.
Harbour shared critical benchmarking data from tooling shops
and discussed ways that mold builders can take the value of
what had been presented at the conference home and implement
it immediately into their businesses to drive and accelerate
profitability. With an emphasis on flexibility as a critical element
in future growth, Harbour outlined what companies need to do
now to improve their businesses and prepare their systems and
processes for the future.
Technology
Sessions
“Get Up to a 500% Annual Recurring
Return with ERP Software”
Dusty Alexander, President, Global Shop Solutions
Enterprise Resource Planning (ERP) is a management
technology that successful companies implement because it
eliminates the wasted time and steps of maintaining manual
(photos ©2011 Todd Schuett, Creative Technology Corp.)
databases. Everything can be linked to the ERP system, including
engineering. ERP systems can manage time and attendance,
provide live scheduling systems and document control,
eliminating the 20 hours a week it would typically would take
someone to key in the data on a spreadsheet.
“ERP systems can help you track your tool inventory,” Dusty
Alexander suggested. “Bar code your tools and put them into
a vending machine. You can track who uses each tool and cut
tool usage by 40%. Using a min-max inventory system, when a
particular cutter or tool gets down to the minimum the vending
machine and ERP system will automatically order more of that
particular tool.”
Using an ERP system to help manage your shop, Alexander said,
“will not only eliminate manual data bases and spreadsheets, but
you can save approximately 1% annually on direct labor and 5%
on indirect labor, which is a very good return on investment.”
“Laser Ablation”
Martin Gorski, GF AgieCharmilles
LASER Ablation is a new method for designing a texture
and wrapping it around a tool. LASER (Light Amplification
by Stimulated Emission of Radiation) ablation is light power
transformed into thermo machining using Ytterbium fiber
laser hardware in either 20W or 50W strength. Martin Gorski,
head of sales, West for GF AgieCharmilles, gave a technical
presentation on this new technology that was just introduced to
North America at the IMTS show last fall.
With their own Laser Ablation equipment, moldmakers are less
dependent on subcontractors, claims Gorski, and they can use the
technology as a means to develop and even patent or copyright
their own textures and designs, thus adding value for their
customers and opening the doors to new business opportunities.
[See the Laser Ablation article on page 24 for more details about
this exciting new texturing technology.]
“Micro and High-Precision Machining”
Andre Ey, Vice President Die/Mold, Makino
Micro molds are not big. Machining for micro molds can be a
challenge and the machine tools for micro machining has only
page 20 u
www.amba.org 19
 Convention
t page 19
recently hit the North American market. Makino has identified
the U.S. market as one in which this technology promises strong
growth. That’s different than a few years ago when Andre Ey
said they “couldn’t sell these micro machine tools into the U.S.”
The difficulty is the metrology. “If you cannot measure the part
how can you know it’s good?” he asked hypothetically. “You
have to invest in metrology to measure micro parts.”
And, it’s not just small molds for very small parts, but many
components today have “micro features” (known as “feature
miniaturization”) even though the part itself might be larger.
Mold manufacturers that begin offering micro molds as a
capability can use this as a “differentiator,” Ey said. “Micro
molds can be a differentiator, and you don’t have to compete
on price.”
“Paperless Manufacturing”
Jim Davis, Pre-sales Solutions Consultant, Siemens
PLM
Siemens PLM NX Mold Design software has been getting rave
reviews from moldmakers and that’s because of the many benefits
this software offers them. Some of those benefits, according to
Jim Davis, include being able to formalize the design process,
save the design templates from specific mold types and reuse the
data. “You can capture the tooling design knowledge and reuse
these proven designs,” he said.
Thomas Duffey, Plastic Components, Inc.,
convention presenter
20 the american MOLD BUILDER Spring 2011
Other benefits include the fact that the NX contains a proprietary
code with electronic build-up, and all information is in real time.
“It makes intuitive 3D visual information seamless; and unifies
design and manufacturing with synchronous modeling,” Davis
said. “You don’t need prints on the floor. It also reduces design
time by eliminating unnecessary drawings. Plus, you don’t get
false readings of draftings and tolerances.”
Best Business
Practices
“Lessons of a Business Transformation”
Thomas Duffey, President and Owner,
Plastic Components Inc.
Learning to be competitive and profitable in the United States
is something that Tom Duffey achieved once he began asking
himself the tough questions. From 1989 - 2005, he purchased
800-900 tools from his mold suppliers in the state of Wisconsin.
However, by 2005, he was losing a lot of business because of the
tooling cost. By 2008, he had purchased 150 molds form China.
“We felt terrible about it,” said Duffey.
Mold companies were getting better, faster and finding ways to
get the cost out of molds, and by 2010, Duffey had come home.
That year he purchased only two molds from China and 48
from his Wisconsin suppliers. “If my customers had the choice
of paying $40,000 for a mold in eight weeks from a domestic
Best Practices Panel: (l. to r.)
Thomas Duffey, Plastic Components, Inc.; Andrew Baker, Byrne Tool &
Die; Steve Kimm, M.S.I. Moldbuilders; and Michael Bohning, Creative
Blow Mold Tooling

supplier or $22,000 for a Chinese made mold in 12 weeks, they’d
take the U.S. mold in eight weeks,” Duffey explained.
Duffey asked attendees to ask themselves five questions to help
them be successful:
1. Do you have a plan? Just a simple, one-page plan that gives
you some idea of what you want to do with the company.
2. Do you have a distinct competitive advantage? Can you
verbalize this in one sentence and would your customers agree?
3. Do you have a marketing plan and a sales strategy? Or do
you just run around and “look for work?”
4. Do you really know how/why/when you are making or
losing money?
5. Do you empower and trust your team?
“Where in your organization are your making money? Where
in your organization are you losing money?” Duffey asked. “To be
profitable, you’ve got to know!”
Best Practices
Panel
“Better Practices at BTI – Lean Manufacturing”
Andy Baker, Project Manager, Byrne Tool & Die
Byrne Tool is a 16-person mold shop in Rockford, MI, that
has become more successful and profitable by implementing
Lean processes. In fact, Andy Baker said that the company has
reduced its lead times on molds by 25%. “It’s nothing new that
we’ve created. We just implemented what we’ve learned,” he
said. “We do what we do for the results. We need to improve
the process through Lean Manufacturing and the people through
organizational development.”
Implementing Lean requires “commitment and strategic focus”
to align the work with your goals, Baker told attendees. Just
having a clean shop did a lot for the company. “We once won
new business strictly because our shop was clean when the
potential customer came in for a plant tour,” said Baker.
The company also improved its manufacturing cycle efficiency.
“Value-add activity is when you’re making chips,” said Baker.
“Non-value add is everything else. Lean focuses on the entire
(photos ©2011 Todd Schuett, Creative Technology Corp.)
process.” Some of the Lean practices really didn’t cost a lot of
money, such as organizing tools by having a box for every tool,
which eliminated double ordering of tools.
“Start with the end in mind,” advised Baker. “Use creativity over
capital.”
“Mold Manufacturing Metrics”
Steve Kimm, Operations Manager, M.S.I. Mold Builders
Located in Cedar Rapids, Iowa, M.S.I. Mold Builders began
implementing Lean a number of years ago. So, how does a
company know when it’s making progress on its efforts? You
have to measure your progress. Get the metrics, noted Steve
Kimm. Measuring provides a fact-based basis to understand
improvements. It can also be used to benchmark for your
competitiveness in the market.
M.S.I. measures several areas of the business:
1. Sales per equivalent employee
2. Sales for the month per equivalent employee
3. Value add per equivalent employee
Kimm said that value add is a measurement that factors in
outsourcing of work that can help a company determine whether
they should make or buy certain components, which impacts
sales. “You did more sales, but did you do more value add?”
Kimm asked the attendees.
page 22 u
Steve Kimm, Operations Manager, M.S.I Mold Builders
convention presenter
www.amba.org 21
 Convention
t page 21
M.S.I. also measures EDM errors per hours worked; number
of welds per hours work; sales per square foot; and labor and
material as a percentage of sales. “As the manufacturing process
matures, labor becomes increasingly less,” he added. “Metrics
lets you know whether you’re winning or losing. Metrics is fact-
based and takes out the subjectivity, eliminating finger pointing.”

“Our Introduction to Lean Manufacturing”

Michael Bohning, President, Creative Blow Mold Tooling
When Michael Bohning purchased this Lee’s Summit, MO,
maker of extrusion blow molds for HDPE bottles for things like
motor oil, gas cans, juice and other types of products in 2006, no
one knew anything about Lean Manufacturing. Bohning, who
has an accounting background and also served as a management
consultant, knew the benefits of improving operations and
Winning team from the AMBA convention bowling
making the 35-person company more profitable.
team building event.

With help from the Missouri Manufacturing Extension

Partnership program, Bohning began educating the employees
about Lean Manufacturing. The first initiative was Value Stream
Mapping – “looking end-to-end how products move through the
manufacturing process,” he explained. The process involved
several steps:
1. Establish a multi-functional team
2. Pick a product family and measuring the critical path to
getting the mold built
3. Identify the bottlenecks in the process and their cause
4. Reorganize the shop to facilitate work cells
“We were able to take a mold build from 12 weeks to 4-5 weeks,
and the employees began to see the value of what we were
doing,” said Bohning. “Never accept the status quo – continually
improve.”
Networking
In addition to all the educational convention presentations, a
Welcome Reception was held on March 2, in one of the many
fabulous cocktail lounges at the Red Rock Resort. The event
was sponsored by Vega Tool Corp. and Makino. It was a great
opportunity for everyone to get to know new attendees, reunite
with old friends and peers and enjoy the evening. The food was
great, and the networking was better than ever!
On March 4, all the convention attendees participated in a
team building event in the VIP Bowling Alley at the Red Rock
Resort. If you’ve never played Charades and bowled at the same
time, you don’t know what you’re missing! But that’s nothing
compared to the second event in which team members were
required to bowl backwards, sitting down and even blindfolded!
The team building event was sponsored by DME Company, and
we thank them for helping to make this a successful event.

AMBA Executive Director, Troy Nix; AMBA Managing Director, AMBA convention attendees visit with suppliers
Kym Conis; MoldMaking Technology Magazine Publisher, during the table top fair.
Claude Mas; and Mike Armbrust, AMBA President.

22 the american MOLD BUILDER Spring 2011

After the team building event, two of the AMBA member
companies sponsored Craps lessons for those interested in
gaining some knowledge and skills in this game. Thanks to Mold
Craft Inc., Willernie, MN, and Craftsman Tool & Mold, Aurora,
IL, for sponsoring this fun time for the members.

The Gala Dinner that evening was sponsored by DMS and

Progressive Components, and the AMBA thanks these two
companies for helping to make this annual affair a great time for
all the attendees. Awards were presented to the Mold Builder
of the Year and to the Chapter of the Year. The newly elected
Directors for the AMBA Board were introduced and first-time
attendees were acknowledged. Also, the team building event Attendees enjoy the Gala Dinner.
winners were awarded their ribbons. (l. to r.) Andrew & Sue Baker with Walter Stuermer.

We’d also like to thank all our other sponsors who helped make
the 2011 Annual Convention another great success:

• Creative Technology: Audio-Visual Equipment
• EDM Network: Lunch on March 3 & 4
• Mold Base Industries: Continental Breakfast on March 3 & 5
• Makino: Continental Breakfast on March 4
These great sponsors also are our great suppliers of the many
high-quality components and products they provide to members
of the AMBA to build the high-tech, state-of-the-art molds that
these companies have become known for. Working together
we’ll ensure the success of the mold manufacturing industry! 

www.amba.org 23
 Technology
The Introduction of Laser Ablation for
Surface Texturing
By Gisbert Ledvon, Business Development Manager, GF AgieCharmilles
In many industries, surface texture has become an important
aspect of product design. It not only provides the means to refine
the physical appearance of an item, but also allows a company to
influence users’ tactile impression of their products. Command
of this subtle interaction offers the opportunity to convey to
customers a subconscious, and in some instances conscious,
indication of product quality. It is of no surprise that moldmakers
are increasingly seeking out ways to improve the level of control
exerted in surface texturing.
Traditionally, one of two technologies has been employed to
provide mold texturing. Moldmakers with five-axis machining
capabilities may use them for creating textures in addition to
general machining. This can be an acceptable alternative if
the shop has excess five-axis capacity or only a relatively
small percentage of jobs that require texturing. Otherwise, the
opportunity costs quickly accumulate, as the equipment could
be more productively utilized with roughing and finishing
operations than with time-consuming texturing. Additionally,
texturing in this manner requires very small, specialized tools,
which increases the cost of the process.
Far more commonly, moldmakers turn to chemical etching.
Compared to five-axis machining, this method offers substantial
time and cost savings. Unfortunately, it also requires sacrifices
in the areas of consistency and quality, due to the impossibility
of precisely controlling the texture produced. Chemical etching
also is more than a little unfriendly to the environment, an issue
of increasing importance for many manufacturers.
Laser ablation allows companies to impart highly
detailed, highly repeatable surface textures to molds,
thus providing increased product differentiation.
24 the american MOLD BUILDER Spring 2011
Recently, a new technology has emerged for surface texturing
in the form of laser ablation. Already used in a variety of
applications ranging from surgical procedures to production of
superconductors, the process entails using a laser to sublimate
material, or turn it directly from solid to gas. Laser ablation
centers can be equipped with pulsed, fiber-optic lasers of varying
strengths and utilize a variety of lenses with different focal
lengths to maximize productivity. The process promises several
key advantages to moldmakers requiring surface texturing.
Laser ablation offers far more precision and accuracy than can
be achieved via chemical etching. No matter how much care
is taken during etching, it is impossible to eliminate variation
that results in a minimum of slight differences between work
pieces. Laser ablation centers produce textures directly from
digital files, allowing the creation of any number of identical
components. Some manufacturers may think that variation is
acceptable between components, but it becomes a much more
apparent issue when thinking in terms of complex molds that
require multiple inserts. In those instances, differences between
the various inserts can result in a visibly inconsistent surface
across the part. Laser ablation eliminates the need for this
sacrifice in quality.
Laser ablation centers use pulsed, fiber-optic lasers
to create textures by sublimating material.
Laser ablation also has no environmental impact, another
area where it far surpasses chemical etching. This provides
substantial benefit even to those manufacturers unconcerned
about the impact of their operations on the environment.
Because of the nature of the chemicals used for etching, US
companies conducting it must comply with a host of regulations
that substantially increase its price. As an alternative, parts can
be shipped to companies doing business in countries with little
or no environmental regulation, an option that brings with it
substantial lead times and low flexibility in responding to urgent
needs. In short, laser ablation often will be cheaper or faster than
chemical etching, depending upon whether viewed in terms of
domestic or international alternatives.
In addition to adherence to strict government regulations,
chemical etching also requires substantial manual labor. Each
part undergoing the process must be carefully prepared to
ensure that the chemicals only access the features to be textured.
Exposing other areas of the component to these chemicals can
result in the entire piece being scrapped. Additionally, the
process requires readying the chemicals, administering the bath,
cleaning the part and disposing of the chemicals, all steps with
high-labor components.
Lastly, laser ablation opens the door for greater legal protection of
innovative designs. The lack of repeatable results with chemical
etching renders the process unable to create textures that could
be submitted for patent protection. Laser ablation overcomes this
hurdle, allowing moldmakers to create and protect surfaces that
result in a truly unique appearance and feel in the final product.
With today’s high demands for product differentiation, laser
ablation centers provide moldmakers with a new, unique means
to meet and exceed their customers’ needs. By incorporating
previously unattainable levels of quality and repeatability, a
shop utilizing laser ablation will quickly stand out in the sea of
competition. 
For more information contact GF AgieCharmilles, at 847.955.7164,
gisbert.ledvon@us.gfac.com or visit the website at
www.gfac.com/us.

In contrast, laser ablation consumes very little labor. An operator

sets the part in the machine, loads the program and walks away
until the texturing is complete. While the actual process time of
laser ablation will substantially exceed that of chemical etching,
the ability to run fully unmanned minimizes labor utilization.
The only true operating cost of the process is the cost of the
electricity consumed.

Laser ablation provides an ideal method of creating unique,

detailed surface finishes on electrodes for die sinking EDM.

www.amba.org 25
 Technology

EDM of Copper Beryllium Mold Materials

By Technical Service Department, Materion Brush Performance Alloys

EDM of copper beryllium can be performed safely and effectively Table 2

using conventional processes and equipment that are commonly EDM Performance
used for EDM of steel. However, because copper beryllium has
much greater thermal conductivity (a significant advantage in MRR TWR
molding plastics) compared to steel, the actual EDM operation g/min in3/hr
requires more input energy. To obtain optimum results with MoldMAX .82 .36 .33
copper beryllium, the EDM parameters will require processing
adjustments compared to steel. EDM of copper beryllium can PROtherm .82 .22 .87
usually be done at 80-100% of the penetration rate for steel while
maintaining a smooth surface and acceptable electrode life. Table 2 shows MMR is the metal removal rate. TWR is the ratio
of electrode wear to work piece removed by EDM.
Like steel, the EDM of copper beryllium produces a thin layer of
recast metal on the worked surface. But unlike steel, this layer is Table 3 shows the effects of variations in the machining parameters
ductile and does not lead to polishing problems or cracking of the on EDM performance. Explanation: If the on-time is increased
mold. The thickness of the affected layer in copper beryllium, (+), this results in a decrease (-) in MRR, a decrease in TWR and
which can be controlled by adjusting the machining parameters, an increase in the surface roughness.
is typically in the range of 1-10 μm. Because the thickness of
the layer is insignificant, it has no measurable effect on mold Table 3
performance. In addition, thermal stress cracking during EDM
MMR TWR Roughness
of copper beryllium is not a problem because of the material’s
unique ability to evenly dissipate the thermal energy of the EDM On-time +- -- -+ +-
process Current +- +- -+ +-
Duty Factor +- +- +- +-
Diesinking
Table 1 sets out recommendations that produced the best Polarity +- +- -+ -+
combination of metal removal rate (MRR), tool wear ratio
(TWR) and surface condition in diesinking evaluations. These Table 4, observations were made during the machining trials
values will vary somewhat depending on design, equipment and using different electrode materials.
electrode selection and should be used as a starting point for
determining the parameters that are most suitable. Table 4
Pure copper electrodes generally provide the best combination of
Many EDM references recommend “standard” polarity
(electrode negative) for EDM of all copper alloys. Testing, EDM Electrode Effects Compared to Copper
however, exhibited better performance with the “inverted” Copper Tungsten Decreased TWR, no effect on MRR
(electrode positive) polarity. or surface

Table 1 Graphite Increased TWR, increased MRR,

(POCO-EDM-3) unstable at high currents and low on
Recommended EDM Parameters for Copper Beryllium times, rougher surface
Voltage 220 V
electrode durability and cost. Pure copper is used in most copper
Current 50 A
beryllium EDM applications. Tungsten copper provides better
Pulse On-time 32 μsec tool life but is more difficult to machine. The price of tungsten
Duty Factor 50% copper is significantly greater than pure copper. In general,
Electrode Gap 305 μm tungsten copper electrodes provide better results in deep, narrow
cavities that are difficult to flush.
Electrode Polarity Positive
Electrode Material Copper

26 the american MOLD BUILDER Spring 2011

Wire EDM Direct-Flo
TM

Tables 5 and 6 provide data from testing done on a Charmilles

Wire EDM machine with soft brass and brass-on-copper wires.
Gold Systems
Table 5
For Maximum Machining Speed
For Technical
MoldMAX PROtherm Molding
Capacitance μF 3.3 3.3 I Designed for Engineered
Current A 48 48 Resins
Pulse Duration μsec 1.6 1.6
Frequency kHz 25 29 I Unitized and Integrated
Systems
Table 6
I Leak Proof Design
For Smoothest Surface
MoldMAX PROtherm I 14 Gating Options
Capacitance μF 0.3 0.3
I Dual Heater
Current A 8 12
Pulse Duration μsec 1.6 1.6
Frequency kHz 17 20

Safe handling of copper beryllium

Handling copper beryllium in solid form poses no special health
risk. Like many industrial materials, beryllium-containing
materials may pose a health risk if recommended safe-handling
practices are not followed. Inhalation of airborne beryllium
may cause a serious lung disorder in susceptible individuals.
The Occupational Safety and Health Administration (OSHA)
has set mandatory limits on occupational respiratory exposures.
Read and follow the guidance in the Material Safety Data Sheet
(MSDS) before working with this material.

Safety precautions should always be followed in EDM of any

material to prevent worker exposure to hazardous materials.
EDM of copper beryllium produces fine metallic particles. To
prevent airborne exposure to these particles, the work piece INCOE® Hot Runners Today
should be fully immersed in dielectric fluid and adequate flow DF Gold Systems are designed for optimal performance and
should be maintained to effectively flush the EDM swarf from cost effectiveness in technical molding applications. With
the electrode area. The EDM equipment should be operated more than 50 years of in-field experience, we partner with
to minimize vaporization of the dielectric fluid. Local exhaust our customers to help them exceed their expectations.
ventilation during EDM is recommended to control exposure That's INCOE® performance ... Right From The Start
to dielectric mist and metal particulate. During machine North America | Europe | South America | Asia
maintenance, the accumulated chips must be handled in a manner
to prevent workplace air contamination. Disposal of machining INCOE® Corporation
1740 East Maple Road
chips should be done in compliance with local regulations.  Troy, Michigan 48083 USA
T: +1 (248) 616-0220
F: +1 (248) 616-0225
For additional information on safe-handling practices or E: info@incoe.com
technical data on copper beryllium, contact Materion Brush www.incoe.com
Performance Alloys, Technical Service Department at
800.375.4205.

www.amba.org 27
 Association
AMBA Plant Tour Workshop
Integrating Design Innovation with a Maximum Automation Approach to Build a Sustainable Business Model

June 14, 2011, 9am - 1pm CST • Hosted by Mold Craft, Inc., Willernie, MN

Leading company executives in the on-going investment in technology has enabled Mold Craft
moldmaking community continually look to grow sales without adding significant amounts of human
for ways to improve the management of resources.
their business and technical operations. To create best-in-class
operations and maximize productivity, machining leaders are Benefits of attending: During this tour workshop, participants
constantly seeking methods to increase output, reduce labor will have the opportunity to tour the Mold Craft facility, engage
inefficiencies and improve profitability. in structured cross-talk with other senior machining professionals
on various aspects of running profitable moldmaking companies
In its quest to become a better machining company, the and discuss continuous improvement opportunities and best
management team at Mold Craft, Inc. has taken aggressive steps practices observed during the walk through.
to utilize technology and integrate automation in nearly every
job it processes. Mold Craft has evolved into a design-intensive For both AMBA member companies and non-member
company, starting from the moment a job is quoted. With the companies, this is a professional development workshop you
goal of minimizing “operator input” simply don’t want to miss!
This event is sponsored by AMBA Partners
during the machining process, Mold
Craft invests time and extensive Progressive Components and Erowa Technology, Inc. Registration information online at
resources to minimize labor and www.amba.org/Tour_Workshop_1.php
maximize unattended machine or call 847.222.9402 with questions
time. Coupling this design-intensive about this event.
strategy with a significant and

2011-2012 AMBA Scholarship Grainger Discount Program Announced

Program for AMBA
Members Employees
AMBA’s National Scholarship Program has awarded over
$211,000 nationally since the program’s inception in 1991. The
Annual Scholarship Program continues to demonstrate AMBA’s
commitment to the industry, education and offering valuable
member benefits. Scholarships will be awarded to employees
or employee dependants. The employee has to be working full-
time for at least one year in order to participate in the program.
Previous scholarship recipients are eligible to apply for the
2011/2012 scholarships.
Authorized by the Board of Directors, AMBA will grant up
to ten - $1,000 scholarships for the 2011-2012 school year.
Scholarships are paid directly to the educational institution.
PLEASE NOTE: Member company owners and/or major
stockholders and/or their spouses and dependents are not eligible
to receive any scholarships.
The selection process will be conducted by the AMBA Education
Committee, consisting of members from the AMBA National
Board. Applications must be submitted by May 27, 2011. For
more information on the AMBA scholarship program visit
the website at www.amba.org/AMBA_Scholarships.php.
Questions? Contact Sue Daniels at 847.222.9402 or email
sdaniels@amba.org.
AMBA is pleased to announce its newest economic impact
program with W.W. Grainger, North America’s largest supplier
of maintenance, repair and operational parts (MRO). Because
all moldmaking operations utilize consumable products (safety,
health, sanitation, etc...) and industrial items (motors, lighting,
grease, oil, material handling, electrical, etc...) and mechanical
repair parts, AMBA’s leadership team has approved an aggregate
buying affinity program that will allow for significant savings for
participating AMBA members including the following:
• Over 1000 commonly used items 40% average discount
• Industrial motors 28% average discount
• Janitorial & sanitation 15% average discount
• Hand and power tools special pricing
• Free shipping on all orders 6% average savings
• Vendor managed inventory programs
Current AMBA Members who are not currently affiliated with
a national account program will be automatically upgraded
in the Grainger system to receive this new AMBA member
benefit. Those who are currently assigned to a national account
agreement will need to compare and contrast to determine which
program provides the greatest amount of value and savings. For
those members who do not have a current account with Grainger
but would like to take advantage of the new AMBA Affinity
program, simply call the AMBA offices at 847.222.9402 and we
will get you set up.

28 the american MOLD BUILDER Spring 2011

AMBA Exhibits at
PLASTEC West 2011
AMBA exhibited at this year’s PLASTEC West show in
Anaheim, CA, February 8-10. As always, the main goal of the
AMBA when exhibiting at trade shows is to promote AMBA
members and the U.S. mold industry. We distribute the AMBA
Sourcebook to qualified mold buyers and OEMs in an effort to
connect our members with new customers. As in years past,
this is a well attended show and booth traffic was excellent
throughout the three-day event. Exhibiting at this show allows
us to assemble a listing of qualified mold buyer leads, which is
made available to all AMBA members via the Members Only
section of the website at www.amba.org. Login to “My AMBA”
to download the lead list from this show.

Many AMBA members and partners assisted in staffing the

booth, so a special THANK YOU is deserved to those below for
volunteering their time to speak with and answer questions from
show attendees at the AMBA booth:

• Alan Petrucci, B A Die Mold

• Jerry Siedelman, Tech Mold
• Geri Anderson, M.R. Mold
• Lisa Oswald, Allcraft Mold
• Tim Peterson, Industrial Molds Group info@wi-engraving.com
• Tim Ruffner, GPI Prototype
• Jim Liddell, Mold Craft page 30 u

Wisc_Engraving.indd 1 10/23/08 1:33:0

Leverage Your Membership

and Save on Shipping.
Your membership with AMBA entitles you to savings on your LTL (less-than-truckload)
shipments with YRC. This savings program is a free benefit of your AMBA membership.

Enroll and start saving today.

www.enrollhere.net | 800.647.3061 | Associations@yrcw.com

Copyright ©2009 YRC Inc.

www.amba.org 29
 Association
t page 29
New AMBA Board Members Announced
Four directors were elected to serve a three-year term. Read more about the newly elected Board members.
Tim Peterson,
Industrial Molds Group
- Chicago Chapter
Tim presently serves as vice president
of his family’s company, Industrial
Molds Group, in Rockford, IL,
which was founded in 1968. He
began in the moldmaking business
by sweeping floors as a young boy.
After graduating from high school, he
began a moldmaking apprenticeship
program, which lasted four years. He
then went to work at Moldesign for eight years before coming
back to Industrial Molds Group in 1992 as a toolmaker. He began
moving up in the company, becoming lead toolmaker, account
manager and spending two years in quality. In 2006, he began
moving further into the managerial side of the company to his
present position as vice president. Tim believes that American
manufacturing is the backbone to a strong America and is
the mission of the AMBA as it works to strengthen American
moldmaking. Tim has worked to promote the industry both locally
and at the national level, and feels that serving on the National
Board of Directors of the AMBA is an honor and a privilege.
30 the american MOLD BUILDER Spring 2011
Scott Phipps,
United Tool & Mold
- Carolinas Chapter
Scott started in the trade while in
high school 30+ years ago and has
worked from the bottom up earning
his stripes. In 1986, he moved to
South Carolina where he was the
shop foreman at a startup facility,
building die cast dies and plastic
molds, as well as doing repairs and
engineering changes. He made the
move in 1995, starting United Tool & Mold from conception to
what has now grown in to three facilities in 2010, with a 60-man
team focusing on mold repair and engineering changes. Scott feels
strongly about the AMBA, and feels that if we all work together
we can take on all the challenges the world has to offer. Scott
has served on the AMBA Board since 2008, and also serves as
the Carolinas’ chapter president. He currently sits on three trade
schools’ advisory boards to promote skilled trades. His company
has an apprenticeship program and feels strongly that the future
of the industry is in our hands; we have to take charge by getting
involved to inspire our young people and our government.
Mike Walter,
MET Plastics
- Chicago Chapter
Mike Walter is general manager
of MET Plastics and an AMBA
member since 1987. Mike is a strong
supporter of the U.S. moldbuilding
industry and understands the
importance of moldbuilding to the
overall economic strength of the
U.S. economy. He has been active
in the AMBA Chicago chapter
since 1997, where he has served in various roles over the years,
including chapter president, vice president, secretary and his
current position as chapter treasurer. Mike joined the AMBA
National Board of Directors in 2007 and is an active member of
the Governance committee. Other AMBA activities that Mike
has participated in include authoring articles for AMBA’s “The
American Mold Builder” publication and the Chicago chapter’s
“Benchmark” newsletter, active participation in government
relations work and Washington D.C. fly-ins and attendance at
national conventions and conferences. Mike’s hobbies include
biking, skiing and busting out show tunes on hotel lobby pianos.
Wendy Wloszek,
Industrial Mold & Machine
- Northern Ohio Chapter
Wendy is the president of Industrial
Mold & Machine. Wendy grew up in
the company by starting her career
as a mold designer, then engineering
manager and progressing to head
of operations before assuming her
role as president in December ‘08.
Wendy is committed to human
development and IMM’s culture of
learning. Wendy is a Champion member of AME and a MAPP
Board Member. Membership in both organizations frequently
exposes Wendy to lean/advance manufacturing techniques
and the perspective to better understand customers’ needs.
IMM also has a significant focus on the use of technology for
communicating. The company has a developed social networks
and is in the process of combining it with the use of iPads for
storing and retrieving job information, a Center for Learning,
Employee Handbook, etc. Wendy is very proud of the fact
that nearly half of the iPads at IMM belong to people on the
production floor. Wendy lives with her husband and two children
in Chagrin Falls, OH.
page 32 u

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Creative Technology Corp

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www.amba.org 31
 Association
t page 31
Welcome New Members employing 105 people. The company builds both injection molds
Custom
and blow molds, and provides engineering and mold design and
Extreme Tool & Engineering Inc. Components
build of both prototype and production tooling.
Contact: Mike Zacharias, President Precision Die & Mold-Ready Tooling
999 Production Dr. Wakefield, MI 49968 Roush serves the alternative fuel, aerospace and defense, auto-
Phone: 906.229.9100 motive and life sciences industries. Mark Slack, the company’s
www.extremetool.com Director of Operations Tooling Division, said the reason for joining
the AMBA is “to learn more about what is happening in our
Extreme Tool & Engineering Inc. is a returning member to the industry.”
AMBA. Mike Zacharias has built a very successful company
over the past decade. Extreme Tool designs, builds and quali- TJAR Innovations LLC
fies injection molds for a variety of industries. The company has Contact: Jan Arsenault, Vice President
seven injection molding presses and performs mold validation 1320 Lavelle Dr.
and process development systems qualification. The AMBA Xenia, OH 45385
welcomes Mike and his team at Extreme Tool! Phone: 937.347.1999
www.tjarinnovations.com
Roush Manufacturing
Contact: Mark Slack, Director of Operations Tooling TJAR Innovations LLC is a family owned and operated mold
manufacturer and plastic parts supplier located in Xenia, Ohio,
Division headed by owner Tony Arsenault.CUSTOM COMPONENTS The company differentiates
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to store shelf-ready. TJAR provides
Rotating Cores · Syringe & Catheter Tooling · Ejector Sleeves
Phone: 734.805.4427 product development services that
Luer Taper Core Pins ·include product
Ejector Pins & Blades · Punchesdesign,
Die & Stripper Inserts · Die Blocks
www.roush.com assembly, packaging, patent
In-houseassistance and marketing help.
capabilities include CNC Wire EDM, Conventional EDM, CNC
Lathe and Machining Centers, Jig Grinding, Centerless Grinding, OD/ID
TJAR has two products of its Dedtruown
Grinding,on the
Surface market.
Grinding, Honing, andThe Shield™
Polishing.
Roush Manufacturing was founded in 1976 and today comprises is a debris deflector for all gas and Ezellmost electric
Precision Tool Co.powered string
moldmaking and molding in an 110,000-square-foot facility, injuries 727-573-3575 Fax: 727-572-6235
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32 the american MOLD BUILDER Spring 2011

Standard
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Helper is a molded handle cover that slips underneath the metal
Are you an AMBA Member?
handle to help save hands and fingers while carrying heavy
Now, more than ever, it is important to use every
buckets.
resource the AMBA has developed to help improve
the profitability of your business. It is the goal of the
Jan Arsenault said that the reason the company joined the AMBA
AMBA to
is “to stay informed of the industry, get industry information,
changes and updates” to help them keep current.
• Deliver real, tangible benefits to its Members
through cost-saving programs
New Partner Spotlight
• Educate its Members on industry benchmarks
Dijet Inc. and best practices
Contact: David Peck, Vice President/COO
45807 Helm St. • Create invaluable networking opportunities for
Plymouth, MI 48170 staff-level executives
Phone: 800.743.4538
www.dijetusa.com • Drive value and member participation throughout
all levels of the Member organization
Dijet Inc. is a global supplier of precision metal cutting tools
• Strengthen industry awareness through education
for the mold, die and metal cutting industries. The company’s
to cultivate an ongoing skilled workforce
focus on mold manufacturing has resulted in two new products
for moldmaking: a new high-productivity indexable swing ball-
nose end mill designed for multi-directional milling; and a high
For information on AMBA membership
performance indexable S-Cut drill designed for high-quality
visit www.amba.org,
hole-making.
or call 847.222.9402.
The AMBA welcomes Dijet, Inc. as another great partner supplier!
page 34 u

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 Association
t page 33
Chapter Spotlight - Minnesota
The Minnesota chapter is one of the AMBA most active chapters.
It seems it always has a project going, whether it’s working
with the local schools to interest students in moldmaking as a
career or helping wounded soldiers, the Minnesota chapter is
on the move. Tim Bartz, vice president of operations for Mold
Craft Inc. (Willernie, MN), started the effort to help Will Byers,
a veteran of the Iraq war, purchase iPads for soldiers who have
been wounded in Afghanistan.
“We were hoping to raise a thousand dollars or so, but over
the course of about a month we raised $9,400. Some met Mold
Craft’s donation, but many gave much more,” said Bartz, who
delivered nine iPads to Camp Pendleton on March 18 and
presented them to the soldiers personally. The iPads came
complete with the case, ear buds and iTunes cards. All but
two were delivered, but Tim and his wife Kim left those with
the Dana Point Support Group to be delivered to the soldiers.
Another six were purchased and delivered by Steve Rotman,
Scott Phipps and Robbie Earnhardt of the Carolinas chapter to
the Walter Reed Army Hospital.
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34 the american MOLD BUILDER Spring 2011
Bob Byers, Will’s father and a well-known figure in the
moldmaking industry, said that the iPads are a great idea and
allow them to do a lot of social networking while they’re
recuperating in the hospital. “I’m very proud of my son and his
big heart, but it was Tim and the AMBA members that did the
rest. There’s no more patriotic group than the American Mold
Builders Association,” Byers said. See the full story on page16.
The Minnesota chapter plans what it believes to be very
informative meetings for its members. On March 22, the
chapter had good turnout for a meeting with an insurance agent
who helped attendees understand some of the things that might
be changing which will affect business owners.
As of this writing, the Minnesota chapter has scheduled a
meeting on May 24 where the chapter will be awarding four
scholarships for $2,500 each. The chapter is very active in
promoting apprenticeships and supporting apprentices. These
funds were raised by the chapter’s annual Golf Outing, which
has been a huge success over the last 15 seasons. This year’s golf
outing will be held on July 21, and the chapter is challenging
the industry to beat last year’s attendance and get over 100
participants through members, partners and suppliers.
Chapter member company Mold Craft will be the host to the
first nationally sponsored plant tour in June. This is an exciting
event that will be open to all members of the AMBA. They
hope to draw local Minnesota chapter members to this new
event where the goal is to have visitors gain insight and look
at their own operation with a different set of glasses; however,
the hosting company will be able to draw on the visitors’
experiences and quiz them on what they see as potential areas of
improvement. This is a win-win for everybody and the chapter
hopes to promote participation within the chapter. Minnesota is
the beta site for this new event, which will eventually be held in
all the chapters nationwide.
Tentative meetings are scheduled for August 18 and November
10. The Minnesota chapter is a very active chapter and they
hope that they can keep growing.
Chapter News
California
The California chapter of the American Mold Builders
Association met for a social time and introduction to prospects
on April 12 at the Arburg Technology Center in Irvine. Twenty
people were in attendance, which included five member
companies, partners and guests.
During the social time, the attendees were able to freely move
about the training floor of the Arburg facility, meeting old friends
and making new contacts. Arburg also had their staff available to
show and discuss their latest technology and to share about the
training they do with their customers.
Arlington Park Racetrack. More details are available on the web
at www.amba.org/Chicago_Chapter_Meetings.php
Minnesota
The chapter held a general membership meeting on March 22
with speaker Sarah Hartneck, Benefits Consultant, of Associated
Financial Group.
The chapter has also booked the date for their Annual Education
Committee Golf Tournament at Oak Glen Golf Course in
Stillwater, MN. Save the date, Thursday, July 21. More
information to come, but if you have questions call Tom Nielsen
the tournament contact at 651.770.1515.

West Michigan
The chapter has announced its meeting schedule for the
remainder of 2011. The annual chapter scholarship presentations
and dinner meeting will be held on June 7 and details about
that event will be forthcoming. Save the date of August 26 for
the chapter Golf Outing event to be hosted at Egypt Valley
Country Club, to raise money for the chapter scholarship fund.
In addition, mark your calendar for November 8 for the Boulder
Creek Dinner Meeting.

Attendees during meeting part of the evening.

Paul Novak, owner of South Coast Mold, reviewed for the group his
attendance at the recent conference in Las Vegas. Benefits of being an
AMBA member were also reviewed for the benefit of the membership
and the prospect companies.

(l. to r.) Tim Lane, Bohler-Uddeholm; Tony May, Pyramid Mold;

Robert Vaughan, Fairway Injection Molds and John Merlino,
Bohler-Uddeholm, visit during the social time.

Chicago
The chapter held a general membership breakfast meeting during
the amerimold™ trade show on April 13 with speaker Laurie
Harbour presenting “Key Profit Strategies.”

The chapter will host “A DAY AT THE RACES On Sunday...”

on Sunday June 6, for family, friends and business associates at
www.amba.org 35
 Special Report
GHS Bringing Changes to
OSHA HazCom Standard
By Glenn D. Trout, MSDSonline
OSHA announced earlier this year that it plans to publish a final rule
in August 2011 that will align the Hazard Communication Stan-
dard (HCS) with the global hazard communication system known
as GHS.
Mold manufacturers should pay attention to these developments and
plan accordingly since HCS violations rank among the top five most
cited OSHA standards for the plastics industry, and GHS alignment
will result in additional compliance responsibilities under HCS.
What is GHS?
GHS stands for the Globally Harmonized System of Classifica-
tion and Labeling of Chemicals. It was born out of the 1992
United Nations Conference on Environment and Develop-
ment, a.k.a. the Earth Summit, and is intended to create a global
approach to the hazard classifications of chemicals and the
communication of chemical hazards via labels and safety data
sheets. (Under GHS, material safety data sheets (MSDS) are
called safety data sheets (SDS), in addition to more substantial
changes we’ll discuss later in this article.)
GHS is not a global law; it’s a system for classifying chemical
hazards and communicating those hazards to the people who
may be exposed to those chemicals. It uses a building block
approach, which means countries adopting GHS may select
only those aspects of the system it wishes to incorporate into its
own standards. Furthermore, countries that adopt GHS also are
responsible for its enforcement.
The United States played a key role in the development of GHS
and OSHA’s HCS was one of four major chemical hazard stan-
dards that served as the basis for the global system. To date, 67
countries have adopted or are in the process of adopting GHS,
and adoption on a wide scale is expected to enhance protection
of workers and the environment while reducing costs and regula-
tory burdens related to international chemical trade.
What will happen to HCS?
To understand how HCS will be modified, let’s quickly review
HCS in its current form. Adopted in 1983 for the manufacturing
industry, HCS was expanded in 1987 to cover all industries. Today
it covers 40 million workers in over five million workplaces. Its
stated purpose is “to ensure that the hazards of all chemicals
produced or imported are evaluated and details regarding their
hazards are transmitted to employers and employees.”
36 the american MOLD BUILDER Spring 2011
OSHA estimates that there are over 880,000 hazardous chemi-
cals covered under HCS and everyone in the lifecycle of those
chemicals probably has at least some responsibilities. Chem-
ical manufacturers are required to evaluate the chemicals and
products they produce to identify potential hazards, and then
provide information about those hazards via warning labels and
MSDSs to the importers, distributors and end-users that receive
their products. Similarly, importers and distributors must supply
labels and MSDSs to their customers.
End-users and employers must take measures to keep employees
who are exposed to hazardous chemicals safe by preparing
a written hazard communication program, maintaining a
hazardous chemical inventory, ensuring that on-site containers
are properly labeled, providing employees access to MSDSs
for all hazardous chemicals and training employees on the safe
handling of chemicals and how to properly read MSDSs and
warning labels.
Again, employer responsibility under HCS has five key compo-
nents.
1. Written plan
2. Chemical inventory
3. Labels and warnings
4. Employee training
5. MSDS management
After the alignment, mold manufacturers should see that the
overall protections outlined in HCS have not been reduced and
that modifications apply only to those provisions of HCS that
must be changed to align with GHS.
Major changes to HCS
The two biggest changes GHS brings to HCS are to the hazard
classification criteria and hazard communication. GHS hazard
definitions are criteria-based and each type of hazard covered is
considered a “hazard class” – such as acute toxicity and carci-
nogenicity – and unlike in the HCS, most of these hazard classes
also are subdivided into “hazard categories” to reflect the degree
of severity of the effect. This is the concept of “classification.”
With GHS alignment, chemical manufacturers must identify
both the hazardous effect (e.g., carcinogenicity) and how severe
that effect might be (e.g., Category 1 or 2).
GHS breaks hazards down into three classes:
1) health hazards; 2) physical hazards; and 3) environmental
hazards. However, the GHS-modified HCS will only cover
the first two classes, as environmental hazards are outside of
OSHA’s regulatory domain. The EPA will cover environmental
hazards when it aligns with the GHS.
Thanks to the reclassification of chemicals, and changes to
the SDS format, chemical manufacturers and some importers/
distributors will likely need to produce new labels and SDSs that
incorporate those changes.
Biggest impact on mold manufacturers
The second key area of change under GHS is to labels and SDSs,
and these changes will have the biggest affect on mold manufacturers.
To start, while HCS takes a simple performance-oriented
approach to labels (meaning OSHA explains the results it wants,
but not how to achieve it), GHS takes a more detailed explana-
tory approach, providing specific how-to provisions for labels.
With GHS alignment, each container of a classified hazardous
chemical is to be labeled, tagged or marked with the following
elements:
1. Product or chemical identifier clearly indicated at the top of
the label that matches the SDS.
2. Contact information for the product supplier, including the
company name, address and telephone number.
3. Hazard pictograms. Transport pictograms will have the same
background and symbol colors currently used (since DOT has
already aligned with GHS). For all other sectors, pictograms will
have a black symbol on a white background with a red diamond
frame. It’s a far simpler system compared to the current 38 shapes,
colors and symbols being used in just North America today.
Note: GHS allows for a black frame to be used for shipments
within a single country. OSHA, however, is proposing that a red
frame be used regardless of whether the shipment is traveling
inside or outside of the country.
4. The signal word should be clearly marked at the top of the label
beneath the product identifier. GHS permits the use of only two
signal words (and only one at a time) - DANGER or WARNING
- to emphasize the hazard and distinguish between hazard levels.
5. A hazard statement that describes the level of hazard should
appear under the signal word. Signal words, hazard statements
and pictograms have all been harmonized and assigned to each
hazard class and category in GHS. Once a chemical has been
classified, the relevant harmonized information can be found in
HCS under the new Appendix C.
6. Lastly, the label should include the appropriate precautionary
information. Since OSHA does not currently require precau-
tionary statements, this is a key change to HCS. As of now,
precautionary statements in the GHS are not harmonized. The
intent is to harmonize precautionary statements in the future;
until that time, OSHA is expected to mandate the use of the GHS
examples, which it anticipates will end up being the harmonized
statements.
Keep in mind these requirements are for classified hazards.
For unclassified hazards, the shipping label should include the
product name, supplier contact information and as supplemental
information, a description of the hazards and appropriate precau-
tionary measures.
Workplace labeling
GHS allows authorities like OSHA to determine what types of
workplace labels will be required, and OSHA has signaled it will
continue to give employers flexibility in this area by allowing
them to choose “to label workplace containers either with the
same label that would be on shipped containers for the chemical
under the revised rule, or with label alternatives that meet the
requirements for the standard.”
OSHA also will continue to give employers alternatives to
affixing labels to stationary containers and portable containers
used to transfer materials from other labeled containers, so
long as the portable containers remain under the control of the
employee who performs the transfer and are used within a work-
shift.
Also not changing, are the requirements that labels be presented
in English – though additional languages are permitted as needed
– and that labels must not be defaced or removed unless immedi-
ately replaced with new labels.
Safety Data Sheets
MSDSs, as was mentioned earlier, are redefined as SDSs under
GHS and remain the backbone of HCS compliance. The align-
ment standardizes the format and quality of information provided
on the SDS. Under GHS, SDSs are presented in a 16-section
format with a required ordering of sections. It is essentially the
ANSI Standard for SDSs, with a few minor tweaks. The sections,
in order, are as follows:
1. Identification
2. Hazard(s) identification
3. Composition/ingredient information
4. First-aid measures
5. Fire-fighting measures
6. Accidental release measures
7. Handling and storage
8. Exposure control/personal protection
9. Physical and chemical properties
10. Stability and reactivity
page 38 u
www.amba.org 37
 Special Report
t page 37

11. Toxicological information How to prepare for GHS

12. Ecological information
13. Disposal considerations
14. Transport information
15. Regulatory information
16. Other information
To be GHS compliant, an SDS needs all 16 sections; however,
OSHA will not be enforcing sections 12-15, which fall outside
their jurisdiction. SDSs will continue to allow provisions for
confidential business information (CBI), or trade secrets as they
are known in HCS, with the understanding that provisions for
trade secret protection should not compromise the health and
safety of users and claims should be limited to the names of
chemicals and their concentrations in mixtures.
Training
Under OSHA’s HCS revision, employers will have two years
from the effective date of the final rule to train employees on
the new rules. Training should address changes to a company’s
written hazard communication plan, changes to labels and
changes to SDSs.
• Chemical manufacturers are responsible for much of the
work that needs to be done in order to make the entire
system GHS compliant and many (if not most) have already
begun the work of transitioning to the new standard.
Many employers, on the other hand, have only a vague
notion of what it is coming and how to prepare. For that
reason, we will focus on the steps employers can take
to make the transition to a revised HCS a smooth one.
• Have an HCS plan and maintain a checklist of
key plan components and review it regularly.
• Inventory your on-site chemicals.
• Make sure you have a complete and up-to-date library of SDSs.
• Stay current with OSHA on the federal, state and local levels.
• Keep an eye on GHS key dates and how they impact your plan.
• Prepare yourself for the eventual SDS churn,
keeping your archiving needs a priority.
• If you’re still using paper, consider
transitioning to an electronic system.

• Make sure your secondary labeling system is GHS compliant.

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38 the american MOLD BUILDER Spring 2011
Conclusion
OSHA has targeted August 2011 for the publishing of the final
rule to align HCS with GHS. At that time, OSHA also will
announce the effective date for the final rule. Employers will
have to train all employees on GHS (reading labels and SDSs,
etc.,) within two years of the effective date and will have to be
3" x 4" in full compliance within three years.
size for
OSHA understands that during the transition, some employers
$2 each will be following the old HCS and some the revised HCS; to that
plus s/h
end, the agency will continue to enforce compliance, but will
accept adherence to either the new or the old standard.
To learn more, visit our GHS Answer Center at http://blog.
msdsonline.com and check out OSHA’s website at http://www.
osha.gov/dsg/hazcom/global.html . August is right around the
corner; by acting now, you should have plenty of time to prepare
for the coming changes. 
Glenn D. Trout is the president of MSDSonline, a provider of
on-demand compliance solutions for tracking and managing
hazardous chemicals and material safety data sheets (MSDSs,
and other critical environmental, health and safety (EH&S)
information. Find MSDS online at www.MSDSonline.com or
call 888.362.2007.

Maintaining a Culture Shift
How many times have we initiated a change in policy, procedure
or process only to have it be ultimately labeled with the often
used “flavor of the month” moniker? Statements like, “we used
to do that and quit” or “we tried that once and stopped” are
common responses to inquiries regarding attempts to promote
change and improvements in many organizations. These
responses are commonplace for such change efforts as basic as
the 5-S implementation to the more complex implementations
of ERP system modules. The starting, stopping and restarting
of Continuous Improvement efforts in many of the facilities we
visit are indicative of an inability to create “sticktuitiveness.”
In today’s lean organizations, as well as in attempts to create lean
enterprises/cultures, sustenance of change or “sticktuitiveness”
is difficult to achieve for a few of the following simple reasons:
• We often dictate change that has been created by individuals
in a vacuum without achieving the ownership or “buy in” of
the culture to the objective or the approach of the change.
• We neglect to create the correct measures/metrics to track
or communicate the effectiveness of the desired change and
monitor for needed corrections in course or direction through
a robust PDCA (Plan – Do – Check – Act) discipline.
• We do not support the effort throughout the management
team and fail to reinforce the effort with the continued
emphasis and reinforcement required
• We might not include cross functional representation in
the “buy in” of the activity, creation of the appropriate
metrics, and may not achieve management support from all
departments affected.
To address these potential reasons for failure to achieve sustained
change, a cultural shift might be in order. This sustenance of
change requires a culture with a foundation rooted in the values
of transparency, collaboration and trust. If the entity is shrouded
in secrecy, combative without compromise or is suspicious of
the motives, then there is a need to transform the day-to-day
focus to a more positive routine.
There is no “magic wand” that can be waved to realize a cultural
shift overnight. We all have experienced the “crash course”
events that have been conducted to incite change in processes
or operations. We may have made significant progress and
improvements with these focused efforts, but in a lot of cases,
failed to cascade or sustain this progress throughout our business
Inside Track
By Ken McGill, Harbour Results, Inc.
processes. There will need to be a dedicated, over-communicated
effort over a period of time before the desired cultural shift begins
to be realized.
Following a few basic principles can aid in the initial cultural swing.
These also become the basis for reinforcing and maintaining
“sticktuitiveness.”
• Though the word “team” is sometimes overused in
describing the organization’s inter-workings, it is important
to solicit input from the affected group once a clear objective
is defined. A sense of “our ideas are being considered” is
critical and can develop ownership.
• Discussing how to measure, visually broadcast and at what
points to recalibrate the direction and initiative is important.
If the measure or metric is difficult to get on a daily basis,
it may be necessary to redefine the scope of the effort or a
different metric may be needed. Metrics also are the trigger
for celebration when success is realized.
• Raising the visibility of the effort throughout the
organization should be achieved through timely
communication, with the measures being well-publicized
and refreshed daily to establish importance. Establishing
small group follow-up meetings regarding the status
of the effort and needs of the group are critical. This
communication confirms management commitment.
Do not assume that merely assigning plans for change to a
group or individual will create lasting results without the proper
disciplined focus and follow-up management reinforcement. In
the lean enterprises that celebrate the most, the “sticktuitiveness”
of a project, program or initiative has a clear definition of desired
change, a collaborative model for input from all subject matter
experts and cross functional ownership to foster the success of
the effort.
The best manufacturing companies today have worked to develop
this “sticktuitiveness”. They have put countless hours into the
development of the team and the processes necessary to drive this
culture. The results are solid performance on a consistent basis
across all performance metrics including throughput, quality,
productivity, morale and the most important – profitability! 
For more details or if you have questions contact the author
by email at kmcgill@harbourresults.com, or by phone at
248.629.9331.
www.amba.org 39
 Product
MPmax Real-Time Machine
Process Monitoring and
Data Management
Makino (Auburn, MI) releases
its new real-time machine
process monitoring and data
management software solu-
tion, the MPmax (Machine
Productivity Maximizer). By
connecting multiple machines
on a single network to a central-
ized computer, MPmax enables
manufacturers to retrieve, store
and analyze high volumes of
machine data in real time.
MPmax offers data manage-
ment capabilities for a variety
of key machine performance
features, including multiple
machine status monitoring,
machine utilization, alarms,
probe data analysis, spindle
and axis movement, machine
power (available only with the
machine power monitor option)
and tool management work
scheduling. MPmax’s ability
to collect probe data and calcu-
late the Cpk process capability index lets manufacturers track
accuracy performance in critical features to ensure the highest
level of part quality. Its spindle and axis monitoring technolo-
gies record and display axis forces, loads and speeds. This data
can then be used to fine-tune processes for faster cutting speeds
and greater depths of cut. MPmax software provides additional
capabilities for remote viewing, allowing operators and manage-
ment the capability to respond to and track processes as they
occur without interrupting other day-to-day activities.
For more information call 800.552.3288 or visit www.makino.com
DMS Hose Hanger
DMS (Oldcastle, ON) is pleased to announce that they have
developed a product which is an
inexpensive way to keep hoses
from interfering with mold setup
and part removal. The DMS Hose
Hanger is 30% glass filled poly-
propylene for reliable strength. It
can currently accept 3/8 and 1/2 inch hoses and can accommo-
date either two or four hoses. The DMS Hose Hanger allows the
moldmaker to provide an affordable professional appearing value
added feature to their customer.
For more information contact, DMS on the web at
www.dmscomponents.com or by phone 519.737.6743.
40 the american MOLD BUILDER Spring 2011
DME Offers New MoldBasics®
Low-Cost Line of Mold
Cooling Products
DME Company (Madison Heights,
MI), a global leader in mold tech-
nologies, has expanded its popular
MoldBasics® product line with the
introduction of several low-cost
mold cooling products. The new
MoldBasics hose connectors include
sockets, plugs, extension plugs and
replacement seals. They comple-
ment DME’s well-known Jiffy-
Tite® line of hose connectors to
meet a wider range of market needs.
MoldBasics connectors offer high standards of quality construc-
tion at a much lower cost than competitors’ products. All connec-
tors feature leak-proof construction combining brass and stainless
steel. They have a maximum rated capacity of 200 psi and can
withstand temperatures up to 400°F with supplied Viton seals.
The new MoldBasics line offers DME plugs used with either
DME flow-thru type sockets or DME automatic shut-off type
sockets. These connectors are designed for plastics molds and
die-cast dies in water, air or oil lines.
To learn more about DME mold cooling supplies,
visit www.dme.net/dme/products/mold_components.html.
MST Slimline Curve Shrink-Fit Tool-Holder System
SST Single Source Technologies (Auburn, MI) offers MST’s
new Slimline Curve shrink-fit tool-holder systems for “2+3”
and simultaneous 5-axis machining applications. The Slimline
Curve’s unique design offers minimal deflection, high accuracy
and extended tool life even in complicated three-dimensional
applications, such as aerospace blisks and medical implants.
Slimline shrink-fit tool-holder systems feature a slim shank and
rigid base with a stainless steel thermal expansion coefficient
1.6 times higher than regular steel. This design enables manu-
facturers to obtain up to five times the holding-power strength
of conventional taper collets and accuracies within 5 microns
(0.0002” TIR) in difficult-to-reach features.
Slimline shrink-fit tool-holders are available in a variety of
models for optimum accuracy, sizing and reach: Slimline Curve,
Mono, Uno and the two-piece system are widely used in high-
performance machining applications. Geometry data is available
on CD and is also accessible in the following CAM simulators:
Vericut (6.2), Hypermill, Edgecam, Tebis, JBM, Work NC,
G-Navi and Tools V3.
For more SST news, visit http://www.singlesourcetech.com/
tooling-supplies, or call 248.232.6232.
Mold-Master’s Cylindrical Shut-off
Valve Gate System
Mold-Masters’(Georgetown, ON) fully scalable, E-Drive hot
runner configured as a 64-cavity Sprint dual synchro plate
system features a cylindrical shut-off valve gate system running
CSD closures at sub five seconds fully inspected, engraved and
packed into a box. The enabler of this system performance is the
company’s Sprint valve gate nozzle, iFlow manifold technology
and Mold-Masters’ E-Drive servo driven pin actuation system.
The combination of these technologies allows customers to mold
CSD closures at unprecedented rates with pristine gate quality
ensured. The Sprint nozzle design accurately controls temperature
in the gate area while allowing for ample decompression
and precise guiding of the valve pin into the gate. The iFlow
manifold delivers rheologically equivalent melt to each cavity,
allowing for reduced clamp tonnage, more processing window
and longer tool life. The E-Drive pin actuation ensures that all 64
valve pins open and close at exactly the same time with speeds
5 times faster than pneumatic. Client feedback on their success
using E-Drive includes color changes up to 400% faster than
comparable tools, defect rates approaching zero and a 15.5%
better-than-requested cycle time improvement.
For more information visit www.moldmasters.com,
or call 905.877.0185.
High-Performance Inserts
The innovative Beyond™ platform of high-performance tool
grades from Kennametal (Latrobe, PA) has garnered exceptional
reviews from customers worldwide for their long life and
exceptional performance. Now Kennametal is introducing
the first Beyond inserts for Kennametal’s ground-breaking
FixPerfect™ system, promising improved toughness and wear-
resistance, resulting in higher turning productivity and safety.
The FixPerfect system features a proprietary shaped pocket that,
together with a clamping stud, locking pin, and tangentially
mounted precision ground insert, result in high clamping forces
and very low cutting forces for excellent chip control and
improved process stability. The FixPerfect inserts are shaped
to match the pocket, which protects unused cutting edges.
Productivity improves as well because the FixPerfect pin simply
needs to be loosened, not removed, to index the insert.
The new Beyond inserts for FixPerfect share the breakthrough
performance characteristics of the entire Beyond line—micro-
polished edges that improve edge toughness, proprietary post-
coat treatment that reduces depth-of-cut notching, and a fine-
grained alumina layer that enhances coating integrity at higher
cutting speeds 
Visit them on the web at www.kennametal.com for more information.
www.amba.org 41
 CAL E N DAR JUNE
PLASTEC East / MD&M East June 7-9, New York, NY, 310.445.4200, www.plasteceast.com
AMBA Plant Tour Workshop: “Integrating Design Innovation with a Maximum Automation Approach to
Build a Sustainable Business Model,” June 14, Willernie, MN, 847.222.9402, www.amba.org/Tour_Workshop_1.php

Chicago Chapter - A Day at the Races, Sunday, June 26, Arlington Park, Arlington Heights, IL,
708.301.0373, www.amba.org

JULY
Annual Minnesota Chapter Golf Tournament Oak Glen Golf Course
Thursday, July 21, Stillwater, MN, 651.770.1515, www.amba.org

SEPTEMBER
PLASTEC Midwest/MD&M Midwest September 20-22, Chicago, IL, 310.445.4200, www.plastecmidwest.com

Pack Expo Las Vegas 2011, September 26-28, Las Vegas, NV, 866.833.3569, www.packexpo.com

NOVEMBER
EuroMold 2011 November 30 - December 3, Frankfurt/Main, Germany, www.euromold.com

Ad Index
A. Finkl & Sons Co...................................................... www.finkl.com ..........................................................................23
AMBA......................................................................... www.amba.org.....................................................................38, 41
Creative Technology.................................................... www.creat.com...........................................................................31
Crystallume Engineered Diamond............................... www.crystallume.com................................................................30
CVD Diamond Corporation......................................... www.cvddiamond.com...............................................................25
Dayne Mold & Die Supply Inc.................................... www.daynesupply.com..............................................................32
DME Company............................................................ www.dme.net..............................................................................33
D.W. Sales................................................................... email: sales@dwsalesinc.com......................................................5
EDRO Specialty Steels, Inc......................................... www.edro.com...........................................................................35
Ellwood Specialty Steel............................................... www.elwd.com...........................................................................14
Erowa Technology, Inc................................................ www.erowatech.com..................................................................34
Ezell Precision Tool..................................................... www.ezellprecision.com............................................................32
Gibson Insurance Group.............................................. www.gibsonins.com....................................................Back Cover
Incoe Corporation........................................................ www.incoe.com..........................................................................27
Makino......................................................................... www.makino.com............................................Inside Back Cover
Millstar, LLC............................................................... www.millstar.com........................................................................9
Progressive Components.............................................. www.procomps.com........................................ Inside Front Cover
Regal Components....................................................... www.regalcomps.com................................................................32
Robb Jack Corporation................................................ www.robbjack.com....................................................................30
Rocklin Manufacturing Co.......................................... www.rocklinmanufacturingco.com............................................30
Ultra Polishing Inc....................................................... www.ultrapolishing.com............................................................15
Wisconsin Engraving Co. Inc. / Unitex....................... www.wi-engraving.com.............................................................29
YRC, Inc...................................................................... www.enrollhere.net....................................................................29

42 the american MOLD BUILDER Spring 2011

 Makino
WIRE EDM

The DUO wire EDM “cuts” everything better, even wire expenditures (by up to
60 percent). Makino combines a number of unique technologies in its DUO wire EDM,
including a dual spark generator, dual flushing pumps for independent control of upper and
lower flushing pressure, and a dual wire-guide option for the widest range of applications of
any wire EDM today. It’s a combination that cuts not only wire expenditures by up to 60%,
but also EDM time by up to 30%—all while delivering a high-quality part. To see how much
you can save, go to makino.com/wirecalc.

© 2011 Makino
 Protecting AMBA

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