Many people come to DeKALB Molded Plastics because we can make large parts. Large parts, structural foam, gas assist, very, very well. We can make products up to 150 pounds at our facility, but really it’s the type of process that we can do. Because they are so large, we can be cost effective with the rate reduction, and again, providing the characteristics that you need for your large part. We present warp, creep, all the building stresses that come with an injection molded part go away with structural foam.
DeKALB Molded Plastics is a leader in the plastics industry with a specific focus on providing injection molded solutions for structural plastics. Our team has the advanced capability to offer metal to plastic conversion, which offers several advantages to OEMs looking for reduced costs and efficient manufacturing. This process has proven that large, plastic components can be manufactured to be just as durable and strong as their metal equivalents, which means significant advantages for our customers:
Reduced Costs of Final Products
Production of plastic parts is more consistent
Product weighs less and reduces shipping and operational costs
Less waste and more consistency of final products
Improved Manufacturing Process
High tensile strength with proper structural design
Reduction in part weight
More flexibility for design
Therefore, if you are looking to cut down on weight and cost, while never comprising the integrity of your product, our metal to plastic conversion specialty is worth investigating. We also offer engineering and design assistance, including program management and product development.
While there are many reasons why metal to plastic conversion might be beneficial to you, below are some answers to our most frequently asked questions.
Metal to Plastic Conversion Q & A:
Why is metal to plastic conversion beneficial?
Customers who have problems with their current metal products, such as inconsistent dimensions or increasing costs for metal often look to plastic conversion as an alternative solution.
What challenges does DeKALB face when using this manufacturing process?
The practicality of metal to plastic conversion has to be considered. Our team is great at communicating challenges and offering both material and design suggestions.
What opportunities are created by using this process? How many of DeKALB's customers either require and/or prefer metal to plastic conversion?
Specialty Material Handling market segment would provide the greatest opportunity for conversion of metal to plastic. Those converted products could include pallets, bins, totes, and carts.
What is a product that was made using the metal to plastic conversion process?
A customer was having issues with a heavy metal automotive seat pallet that was damaging production lines within their facility. They needed something durable yet non-abrasive and plastic conversion was a great alternative.
DeKALB Molded Plastics has completed metal to plastic conversion for a wide array of industries. Communicate directly with our engineering team today to discover the possibility of transforming your metal products to plastic.
I have a product engineer that is very intimate with the tooling process. He does a very close negotiation with the customer and their design staff. He interfaces very closely with the tool shops. We don’t necessarily select or control the operations at the tool shop, but we are very intimate with making sure that it accomplishes what the customer would like to see. That interface between the customer, the tool shop, and my product engineer is very integral to making sure that that all comes together in a successful job.
For the team of experts at DeKALB Molded Plastics, inventory accuracy is a major focus from all levels and aspects of the company. In order to accomplish this, we have established a reliable management system in all phases of production from the hardware (wireless AP), handheld scanners, barcode printers and data entry/collection stations at all presses. By coupling that with a top-notch ERP System and the proper training, we have successfully accomplished a solid management system.
Warehouse management at DeKALB is supported and accomplished through our ERP system (or IQMS). This program enables us to be organized and streamlined by receiving the items, printing barcoded labels and moving materials to the press, as well as scanning labels to ship produced items to our customers.
As stated by IQMS, this program enables our team to properly “monitor, manage, analyze and report on the manufacturing process from end-to-end, giving you real-time visibility and control over your entire manufacturing supply chain.”
By regularly maintaining important steps with our ERP system, we are able to be more efficient, which saves time and money for the customer. Our team is always focused on implementing the following process:
Product is ticketed upon receipt
Product is ticketed once produced
Product is logically organized and categorized
When product is shipped, the tickets are scanned and recorded
Customer Service is Priority
A major reason why DeKALB has invested time and money into an efficient ERP system is to provide cost and time savings for our customers. Therefore, our system is very streamlined to allow for an easy-to-follow set of instructions that pertain to sales orders, pick tickets, resin orders and scheduling. To have a recorded process, which all managers can access and adjust, has substantially reduced the shipping of non-conformance products. In fact, customers have attested to our reliability as there have been zero shipment errors since the inception of the ERP system.