Randall M. Perry, DMP’s president and CEO, has led the company’s transformation into a full-service extension of its customers. DMP’s Nashotah, WI HQ includes engineering, analytical lab services, rapid prototyping, and both thermoset and thermoplastics parts production. A prized possession of our tour guide is this signed portrait of Green Bay Packers QBs Bart Starr (right) and Brett Favre. Moldflow Plastics Insight software allows DMP engineers to optimize process setups. DMP even practices Scientific Molding principles in thermoset molding. Its thoroughly maintained tools are stored in ready-to-run condition. A new FTIR enhances DMP’s extensive materials analysis capabilities. Engineering and materials analysis expertise solve multishot molding challenges. DMP’s mission is to provide advanced technical solutions to customers, like this fully automated molding cell for making technical components.

Under new management, a reorganized, revitalized, 65-year-old U.S. custom molder is making the investments necessary to expand as a technical solutions provider.

If the inspirational headline of this story is unfamiliar to you, you’re probably not from Wisconsin. It’s a quote from Bart Starr, the legendary quarterback of the Green Bay Packers. But the quote also could have come from the inspired executives now leading the lean transformation of a molding operation headquartered in Nashotah, WI, originally known as Dickten & Masch Mfg. Co.

In 2004 Dickten & Masch was purchased by Everett-Smith Group Ltd. (Milwaukee, WI), a family-owned investment company that’s been in business since 1858. Two years later the company was rebranded as Dickten Masch Plastics (DMP). But it was more than a change in name. A brand-new company icon, tagline, website, and advertising plan were launched. According to company officials, DMP’s strategic focus was sharpened to clearly position it as a full-service supplier with the technical services and manufacturing capabilities required to ensure mutual success.

It operates three manufacturing facilities today: thermoplastic and thermoset plants in Nashotah, WI and a thermoplastic plant in Ankeny, IA.

We’ve been told we’ll see ample evidence of the desire, dedication, and everything else it takes to be a full-service 21st century “solutions provider” here in Nashotah. So, let’s tour.

Solutions supplier

Our host is Jason Hynes, DMP’s VP business development. “We’re continuously engaged with our strategic customers to better understand their needs and develop products that help grow their business,” Hynes says, while escorting us to meet DMP’s president. “We’ve initiated a program of sales themes to differentiate us from others by highlighting our technological strengths and resources. As a plastics solutions company, we seek new business opportunities that are aligned with our value proposition. Our marketing tagline, ‘Advancing Technical Solutions,’ means that we provide customers with plastics expertise and creative ways to improve their products through our diverse capabilities.”

“We have developed a proactive strategy to position the business for growth and longevity,” says Randall M. Perry, president and CEO. “We reorganized the business and prudently rationalized the customer base. We were trying to be all things to all people, which can add complexity. Today our growth is focused primarily on infrastructure markets, such as electrical, water and fluid treatment, building and construction, and transportation. We are seeking engineering-driven projects, particularly those involving metal-to-plastic conversion, and turnkey product assemblies.”

He reinforces what Hynes has told us, explaining that customers can rely on the technology DMP offers. Rather than being all things to all people, he says the company aligns with select customers that have plastics needs—requirements for product design, materials selection and analysis, project engineering, production . . . everything.

Engineered excellence

Our next stop is in an area that Hynes calls “Engineering Services.” He says there’s a similar engineering center at DMP Ankeny and adds that the company’s Engineering Services team, including its renowned materials analysis laboratory here in Nashotah, plays a lead role in developing solutions and in helping customers that value having a technical plastics partner rather than just another molder in their supply chain.

“We have a strong team of experienced designers and plastics engineers leveraged across our locations to support customer programs, designing parts with cost, manufacturability, and process efficiencies in mind,” says Hynes. “We’re very deep into Moldflow software as a predictive design tool. Multiple engineers at DMP are highly certified users, and we run the full suite of analytical tools, including warp analysis.”

Other available resources include ProMechanica FEA, ProEngineering, SolidWorks, and Solid Edge software; a 3D Systems SLA system; and a Faro portable CMM for reverse engineering.

We’re amazed, watching an engineer manipulate a complex solid model of a two-shot, high-volume component with a robotically loaded insert. We’re told that DMP will mold it with an engineered resin in an electromechanical unscrewing mold with four slides that the company’s also designing.

Customer concentration

As we walk over to DMP’s thermoset plant, Hynes tells us DMP designs production molds in-house and has them built by local strategic allies or offshore sources. Prototype molds, repairs, and engineering revisions are done in-house. For more than a year DMP has been actively involved in what Hynes calls a “complexity reduction initiative,” ridding itself of older equipment to better position itself for growth and productivity. It has exited what he calls “nonstrategic customers,” consolidated its resin portfolio, reduced its obsolete and slow-moving tool inventory, and implemented a strategy for acquiring new automated molding equipment.

“Our emphasis is doing more for our strategic customers while developing a short list of targeted new prospects who value the services we provide,” Hynes says. “We’re focused on providing engineered components, integrated modules, and value-added assemblies.”

DMP’s 75-person-strong thermoset molding plant has 18-ft ceilings and two 5-ton cranes. You’d expect a plant running thermosets to be a bit warm and dirty. It isn’t, though. The entire facility is clean and cool—air-conditioned, as is the thermoplastics molding plant.

Injection molding is on one side of the shop—presses range from 55-310 tons. Compression molding—200-800 tons—is on the other. The plant has 200 active tools and Hynes says the company’s goal is 100% automated press-side deflashing. Hunziker deflashers are standard.

Lean lead times

For complex parts, DMP has installed dedicated parts-finishing systems. We see an automated routing center with a six-axis ABB robot deflashing and machining parts, for instance. The company has run thermosets for 65 years and its experience shows, both in its application of some of today’s most advanced primary and secondary manufacturing technologies, and in its application of lean thinking.

Regarding the latter, the company’s value-stream mapping activities have driven implementation of a streamlined order-entry process, vendor-managed inventory, and kanban systems. All reportedly have led to significant lead-time reductions and customer delivery scores exceeding 99.8%.

Regarding the former, there are press-mounted Ranger and Star Automation parts-removal robots everywhere. There’s also an “artificial lung” on the shop floor. It preheats molds before they go into a press and cools them down when they’re removed. Hynes says it’s cut setup times in half.

RJG inmold pressure and temperature sensors are prevalent. DMP also uses dielectric cure sensing to ensure repeatable part quality. And Hynes says Scientific Molding process optimization principles are practiced here, as they are in the thermoplastics molding facility—our next stop.

Investment initiatives

Its thermoplastic molding operation is configured into four main cells dedicated to producing similar products, says Hynes: large-tonnage, smaller-tonnage, specialty products, and dual-shot components. Most of the business here is in midvolume, midsize components with tight tolerances for engineered applications. DMP says its materials experience gives it an edge when it comes to running engineered resins and optimized molding processes.

On molding machines ranging up to 725 tons, DMP runs about 600 different parts in more than 500 tools, many of which are equipped with RJG process control systems and run with Scientific Molding methods. It uses quick-change inserts in tools for high-volume runs, such as those involving customer-specific kanban systems.

As we pass two-shot and insert molding presses, Hynes says DMP plans to invest in several new presses in the coming year. “We’re standardizing our line of molding equipment and are very focused on continuous improvement across the enterprise,” he says.

Some of DMP’s individual parts-molding cells are stunning. One bears special mention. A new, fully automated two-shot Engel 500-tonner equipped with an Engel ERC robot is molding and testing technical components.

DMP provides as many value-adding secondaries as it does primary processes. As we pass its enclosed climate-controlled pad printing and welding room on our way out, we’re left with the impression that DMP is a work in progress. Hynes confirms our suspicions.

“We’re excited about launching IQMS’s Enterprise IQ software in Q1 2008. We expect the new system, including its RealTime machine monitoring, to provide a competitive edge. We’re also exploring options to improve material handling systems in our cells. Our goal is to blanket our customers with services, speed-to-market, and solutions.”

That takes desire, dedication . . . everything.

Vital Stats Dickten Masch Plastics, Nashotah, WI Facility size: 255,000 ft² (two plants in Nashotah, plus facility in Ankeny, IA) Annual sales: $60 million Markets served: Transportation, electrical, water treatment, HVAC, building/construction, power/hand tools, lawn and garden, healthcare, food service, appliances Capital investment: Proprietary, but reportedly higher than the industry average Parts produced: Tens of millions/year Materials processed: Thermoplastics including nylon, PPE/PS, TPO, PET, PP, TPU, PPA, TPE, PBT/PET, ABS; thermosets including BMC, SMC, phenolic, epoxy, polyester, vinylester Resin consumption: 35 million lb/year No. of employees: 315 (85 in Iowa) Shifts: Three, five days/week Molding machines: 28-725 tons for thermoplastics (40-3000 tons in Iowa) and 55-310 tons for thermosets (200-800 tons compression molding), primarily Cincinnati Milacron and Engel Molding technologies: Multishot, insert molding, gas assist, microcellular TPR/TPU molding, Scientific Molding, RJG process control Secondary operations: Engineering, materials analysis, assembly, turnkey product packaging, welding, decorating, milling, tapping, drilling, inserting, buffing, deflashing Internal moldmaking: Yes—prototypes in Wisconsin and production moldbuilding capability in Iowa Quality: ISO 9001:2000, Scientific Molding, lean manufacturing Contact information Jason Hynes | (262) 369-5555, ext. 519 www.dicktenplastics.com