Expansion Initiatives Pave Way for Growth at SAY Plastics

To accommodate recent growth and forecasted 2019 growth, SAY Plastics announced it has made several key investments centered around technology, operational excellence and workforce development.

Click photo to see SAY Plastics’ recent expansion initiatives

These investments in capacity expansion have helped the company foster an atmosphere of continuous improvement and learning – hallmarks which the company has been recognized for by both customers and industry colleagues.

As part of the expansion, SAY Plastics announced the following milestones:

Technology

  • An additional 5 Axis CNC Router with 10 position tool changer
  • New advancements in Forming Machine controls and zoned Ceramic Oven technology
  • Upgrades to ERP and Manufacturing Software systems

Operational Excellence

  • Plant layout enhancements to support cellular manufacturing flow – including arrangement of equipment into a processing sequence for forming, trimming and assembly
  • Employee cross-training for flexibility and a multi-skilled workforce across different manufacturing processes 

Workforce Development

Ron Staub, VP and General Manager at SAY Plastics, shared “The investments made over the past year have greatly increased our capacity and our ability to deliver high customer satisfaction. We’re well-prepared for the continued momentum we’re experiencing, and we’re confident in our team’s ability to provide innovative thermoplastic solutions that are of the highest quality and value.”

SAY Plastics’ latest technology and equipment purchases took place earlier this year and are now complete, and new team members were welcomed throughout 2018 and are now in place. The new cellular plant layout is currently underway, along with new technical training for employees.

Want to learn more about how thermoforming can benefit your organization? Contact SAY Plastics to see our expansion efforts first-hand and to meet our newest team members. Call 717-633-3333 or email Ron Staub at info@sayplastics.com.

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SAY Plastics Recognized for Technology Excellence

SAY Plastics was recently announced as a winner of MANTEC’s 2018 Excellence in Manufacturing Awards. MANTEC is South Central PA’s leading manufacturing training & certification provider.

Ron Staub, SAY Plastics VP and General Manager, pictured first on the left receiving MANTEC's Excellence in Manufacturing Technology award.

Ron Staub, SAY Plastics VP and General Manager, pictured first on the left receiving MANTEC’s Excellence in Manufacturing Technology award.

Awards were given to manufacturers that have demonstrated a commitment to improving business through Smart Manufacturing in the categories of: Operational Excellence & Quality; Growth & Innovation; Technology; and Workforce Development.

This year SAY Plastics took home top honors in the Technology category. The award went to the finalist that best accelerated opportunities which leverage and adopt manufacturing technology.  Other category finalists included ACCO Brands, Phoenix Contact, Four Seasons Produce and York Imperial Plastics.

The main initiatives behind this award for SAY Plastics include the company’s SAYtooling System and the use of 3D printed components in collaboration with thermoforming processing.

The SAYtooling System strategy involves tooling design and materials developed around required process and production applications to achieve the most cost-effective project results. This unique engineering-focused process allows SAY Plastics to effectively and affordably produce small part runs. Learn more about the SAYtooling System.

SAY Plastics’ 3D printing initiatives have effectively produced component parts for value-added assembly and prototype development parts. Read about SAY Plastics’ investment in 3D technology here.

Louis Smith, President of SAY Plastics, shared “Our organization has always focused on continuous improvement throughout all areas of our company, and technology is no exception. Our excellence in manufacturing technology helps drive higher quality, greater responsiveness, cost avoidance, and better process capabilities and product development. It’s an honor to be recognized by MANTEC for these efforts.”

To connect with the SAY Plastics team for engineering assistance, or to submit an RFQ, contact us at 717-633-6333 or info@sayplastics.com.

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SAY Plastics Goes Global for Idea Development & Innovation

When machinery builders, material suppliers, toolmakers and processors from around the globe met earlier this year in Rome, Italy to further their knowledge and applications of thermoformed plastics, SAY Plastics was there.

Commercial Heater Door Assembly

SAY Plastics was one of 149 organizations from 31 countries that participated in the 11th European Thermoforming Conference, hosted by the Society of Plastics Engineers – European Thermoforming Division. The global event drew participants from Europe, the Middle East, the Far East and North America.

Attendees gain valuable insights into the industry’s latest technologies, markets and competition and have the unique opportunity to collaborate with peers and customers on a global scale.

“As a North American company, it’s important to remember that thermoforming is a globally recognized engineered plastic process. There are exciting industry advancements happening throughout the world, and by expanding our international alliances and exchanging information and insights on a global level, we can develop greater ideas and innovation for our customers,” shares Louis Smith, President of SAY Plastics.

This year SAY Plastics was honored to have the only North America entries featured in the conference’s technical parts exhibit. The exhibit showcases a wide range of new product developments from leading thermoforming suppliers. Our ClasSAY global ISD components for automotive assembly damage protection solutions were featured, as well as a hot water heater door assembly manufactured for the HVAC market.

Foam Laminated ISD Shielding

Foam Laminated ISD Shielding

Participating in the European Thermoforming Conference is just one example of how SAY Plastics embraces a collaborative, global approach to the thermoforming. We value how much our clients benefit from the diversity of thought that’s generated from global participation in the industry.

If you’re feeling underserved by your current thermoforming supplier, connect with SAY Plastics. Our experienced team can offer engineering and manufacturing expertise to give you a competitive edge.

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SAY Plastics Achieves Continued Certification for ISO 9001:2015

SAY Plastics recently announced that it earned continued accreditation for ISO 9001:2015.

Issued through the Performance Review Institute (PRI) Registrar, SAY Plastics received the accreditation for demonstrating their ongoing commitment to quality by satisfying customer requirements and industry specifications.

“SAY Plastics has demonstrated its commitment to world-class quality by continuing certification to the ISO 9001 standard. They are one of an elite number of organizations worldwide that have achieved certification to this globally-recognized quality standard,” said Randy Daugharthy, Director of the Registrar Program at the PRI Registrar. “We are proud to partner with SAY Plastics in this accomplishment and look forward to continued support of their objective of quality excellence.”

Click here to learn more about SAY Plastics’ ongoing commitment to quality and to view their ISO Certificate.

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SAY Plastics Invests in Project Efficiency with SAYlamination

To provide our customers greater efficiency by avoiding our need to outsource, SAY Plastics and our ClasSAY global group have invested in automated lamination technology.

Our SAYlamination service is backed by our expert design and engineering team and delivers a wide range of thermoformed protection solutions with faster turnaround, better quality and lower costs.

SAYlamination is far-reaching and customizable. Here’s how:

  • SAYlamination can provide laminated foam to your required sheet plastic materials for a wide range of custom protection products and material handling solutions.
  • Our foam lamination also can provide added sound-deadening insulation for many component applications.
  • Material can be used as a flat stock or thermoformed interleaf.
  • We can laminate sheets large enough to fully utilize the size capabilities of our thermoforming equipment and can laminate to thicker substrates for heavy-duty protection equipment.
  • SAYlamination also offers the ability to create multi-layer material systems within a single component – just one of the many advantages of thermoforming over injection molding.

Many Applications
SAYlamination is highly customizable for many industries. We can meet requirements for a variety of sizes, thickness and colors – even at low quantities.

Some of the industries that benefit from our lamination services include:

  • Automotive
  • Construction
  • Ag Equipment
  • Heavy Truck
  • Passenger Rail
  • Bus Transportation

To see how else SAYlamination delivers value, visit our ClasSAY global website. ClasSAY global is a service group of SAY Plastics which delivers comprehensive Class A surface protection products to major automotive OEMs and suppliers to the automotive industry.

To request a free consultation or quote, click here.

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SAY Plastics Launches New Website for ClasSAY global Service Group

SAY Plastics has announced the launch of a new website focused on our ClasSAY global service group – ClasSAYglobal.com.

ClasSAY global delivers comprehensive Class A surface protection products to transportation industry OEMs, their suppliers, and other manufacturing. These products and concepts have application opportunities across all industries providing support to Lean Manufacturing.

The new website highlights our latest innovations and capabilities that have produced cost-saving, high-quality solutions for customers around the world:

  • ISD products: From exterior and interior applications including fenders, seats and consoles to transportation applications like dunnage and racking
  • SAYcup: 100% compatible suction cup design for Class A surfaces. Request your free sample – no purchase is required.
  • SAYpack: Get a more reliable way to pack and ship your parts and erase in-system damage issues.
  • SAYlamination: Our in-house lamination services deliver a wide range of thermoformed protection solutions with faster turnaround and better quality.

We invite you to explore the new website and share your feedback. If you have questions, please contact us. Or request a Free Consultation and see how ClasSAY global can help solve your Class A surface protection challenges.

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SAY Plastics Announces New Hires

SAY Plastics recently announced the hiring of two new employees – Brian Fink and Todd Chrismer.

Brian Fink has joined the company as Account Manager. His role is to support our continued business growth. With a decade of experience in the thermoforming industry, Brian has held the role of Quality Manager, managed large OEM accounts and led many new product development initiatives that have driven innovative solutions, system/process improvements and client cost savings. Brian holds several degrees and industry certifications including a certificate for Heavy Gauge Thermoforming from the Pennsylvania College of Technology, and certifications from the American Society for Quality (ASQ). He also has a specialized degree in Computer Aided Drafting & Design from York Technical Institute and a Bachelor’s Degree in Business Administration from the Indiana Institute of Technology.

Todd Chrismer has been hired as Plant Manager. He brings over 25 years of thermoforming experience to SAY Plastics and is responsible for overseeing all plant operations and our personnel in production, shipping & receiving, maintenance, tooling and CNC. Todd has attained industry certifications including a certificate for Heavy Gauge Thermoforming from the Pennsylvania College of Technology. From thermoforming machine operator to thermoforming plant manager, Todd has worked in various positions over the years, giving him valuable expertise in 5S and Kaizen methodologies, value stream mapping, tooling engineering, work cell layout development and quality control planning. He has also completed many training sessions in Lean Manufacturing and has applied those principals to the plant floor with great success and a high degree of customer satisfaction.

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ClasSAY global – Delivering Class A Surface Protection Around the World

Automotive News (AutoNews.com) recently published a feature article about BMW’s Spartanburg, South Carolina plant, which was established as the first North American plant for the German automaker 25 years ago. Today, Spartanburg is home to the company’s largest assembly operation in the world – having produced over 400,00 vehicles last year.

ClasSAY global, a service group of SAY Plastics, works with major automotive suppliers and OEMs around the globe to design and produce protective packaging and protective shielding, as showcased in the BMW article feature photo.

Read the full Automotive News piece here.

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3D Technology Comes to SAY Plastics

With a focus on continuous improvement, SAY Plastics recently acquired three-dimensional (3D) printing technology at our manufacturing facility in McSherrystown, PA. Since adding 3D printing to our list of capabilities, our engineering teams have successfully made this technology an integral part of our product development and manufacturing processes.

3D Printing Defined

So what exactly is 3D printing? It’s an additive manufacturing process that creates objects one layer at a time, growing parts out of thousands of layers depending on the object’s size. While 3D printing is commonly used for prototyping and tooling, it’s still in the innovation stage for production applications. But the 3D printing process can produce extremely complex parts without tooling and reduce lead times and costs for the right type of component. And 3D printing can be a smart manufacturing alternative when high production volumes aren’t needed.

SAY Plastics’ Investment

SAY Plastics adopted 3D printing in December 2016. When we invested in the technology, our exact uses for the printer weren’t yet realized. But the decision to add the capability came down to our desire to bolster the re-engineering and innovation processes that have fueled our company’s growth in recent years.

Within short order, the SAY engineering team had the printer humming along – producing parts and components that otherwise might have been outsourced or added to our traditional internal toolmaking schedule. Adding 3D technology provides us with a valuable resource that increases our available technical skills, flexibility and capacity.

Examples of 3D Applications

One example of a tooling application using 3D printing is creating plug assists to provide improved material distribution when addressing a challenging draw ratio. Plug assist tooling can help stabilize the repeatability of the thermoforming process. It does this by aiding material distribution and allowing the thinnest possible starting gauge thickness – ensuring maximum detail and temperature optimization and reducing overall costs.

The plug assists that SAY Plastics produces using 3D technology provides greater design freedom and faster product development.

Four corner plug assist components

Four corner plug assist components

Another example of a 3D printed component is a mounting bracket bonded to a thermoformed door assembly for a new generation of commercial industrial tankless hot water heaters. This door assembly required a lightweight, highly aesthetic solution.

The customer originally planned to purchase fabricated steel door structures from China, but due to urgent timing needs and a desire for lightweight and higher cosmetic features, they went with thermoformed assemblies produced by SAY Plastics.

A critical element of the design and development challenges of this project included meeting the project’s expedited timeline, which included in-house responsibility for the LED touch screen mounting bracket component design and supply. For that bracket component challenge, SAY Plastics turned to their 3D printing resource.

This is an excellent example of where 3D printing provides added value to the thermoforming processor. In the end, SAY Plastics delivered the solution that was sought by the end customer – a lightweight door with highly cosmetic design features, and expedited delivery.

Bracket (black component) assembled on door

Bracket (black component) assembled on door

3D Printing and the SAYtooling System

3D technology has proven to be the perfect partner to the SAYtooling System – SAY Plastics’ innovative approach to tooling development. With this corporate-branded tooling system delivering a highly effective solution, SAY Plastics offers a cost-effective entry for new product development, start-up projects, and low/medium volume programs. 3D printing compliments the SAYtooling System in its ability to provide customers with low-cost solutions and minimal lead times to support new product development and small production runs.

Big Results

To date, 3D printing has been a success story for SAY Plastics. It’s an integral part of our product development and the ongoing manufacturing processes that meet our customers’ needs for prototypes and assembly components.

Our current 3D printer has a build area of 11.6” x 7.7” x 6.5”. Our printing materials are ABS and PLA. We foresee purchasing additional printers in order to offer larger size capabilities and increase production. Stay tuned as we continue to explore this exciting technology.

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SAY Plastics is Hiring!

SAY Plastics is a contract manufacturer that is ISO 9001-2015 certified with: Design, Thermoforming and Assembly of Plastic Parts and components. To support continued business growth across our diverse product portfolio, we are hiring for the following positions:

CNC Programmer

Position Summary: Effectively utilize MasterCAM to generate 5 axis tool paths to machine molds and trim thermoformed heavy gauge products.

Qualified candidates will have at least 3 years CNC programming experience. Experience performing CNC programming for thermoform parts and tooling is a plus.


To apply or request additional information, please contact:

Erich Kaintz
VP of Business Development
717-630-5775
ekaintz@sayplastics.com

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