Category Archives: Quality

Dedicated to Continuous Improvement, Dedicated to Quality

With over 40 years of experience in structural foam molding, DeKALB Molded Plastics is proud of the world-class quality reputation we have built. At DeKALB, our mission is to provide unsurpassed customer satisfaction with the products and services that we provide. To achieve this, we have placed a heavy emphasis on continuous improvement, taking a comprehensive look at every detail of our process, understanding there are always ways to advance our capabilities. Our team has established clearly defined standards that help control all process variables, ensuring that every product that leaves our facility meets our standards before they exceed yours.

Standard Process, Custom to You

Being an ISO 9001:2015 company, we take great pride in creating quality parts that our customers can count on. DeKALB Molded Plastics has a standard process for every part that we mold, with established procedures inside of the practice as a whole. Our meticulous quality checks include processes for:

  • Material
  • Melt Flow Analysis
  • Colorants
  • Specifications of the material
  • Value-added inspections
  • Visual inspections
  • Weight tracking

In addition to our standard processes, we also have the flexibility to implement additional verifications and inspections, as required by our customers. Some of our additional quality process capabilities include the ability to complete gage R&R studies, understanding how the measurement determines repeatability and reproducibility, flatness checks to discover how well the part maintains its shape, verification of size and some capability studies. For customers with higher-level requirements or those in the medical industry, DeKALB offers a production part approval process or PPAP submission to ensure that part specifications are met.

What Makes Us Different

Some companies may pass on parts that require too many part inspections, while others do not have the capabilities to do part testing. Being committed to your solutions means that we are dedicated to finding a way to offer a complete custom molding solution, every time.

As part of our growing capabilities to ensure quality, we offer some product testing including:

  • Adhesion testing & plastic welding parts
  • Build up test
  • Falling dart test
  • Other various tests, as requested by the customer

As a custom molder, one of our greatest strengths is our flexibility. We regularly have customers ask us to do specific inspections and verifications for their products. At DeKALB, our customers set the standards for the quality checks and verifications that are completed on their parts through individual runs or set of runs. Far from simply molding a part and shipping it, what separates us from our competition is the number of quality checks we perform, our ability to produce parts in color, and our willingness to do as many inspections as needed by our customers.

Continuous Improvement in Action

Continuous improvement is a way of life at DeKALB, as we constantly strive to advance our company, never being satisfied with where we are. Our culture of continuous improvement means we are always looking at how we can improve our processes, quality, safety and how we can expand our capabilities.

Recently, DeKALB has experienced exciting growth with our expansion in automation and continued additions to our quality measures to support a high grade of aesthetics. At the end of 2019, DeKALB added a new robot, adding to our automation capabilities. Currently, the new robot is being used for multiple customers and will continue to be utilized more.

As DeKalb continues to expand capabilities to suit the needs of our customers, our team recently began working with new programs that require more analysis, including some hot stamping applications for multiple parts, as well as adding labels more accurately. These parts have labels that require very precise placement and have several requirements and standards related to their placement. Our team has added additional quality control measures, helping to improve our ability to meet these needs. Both of these examples are areas that highlight how DeKALB is growing and showcases how we continue to find ways to live out our culture of continuous improvement.

Future of Quality at DeKALB

We are excited to expand our abilities in electronic data collection and use lessons learned to improve our sampling and manufacturing capabilities. As we continue to grow, we maintain our commitment to delivering excellence, ensuring that our products and services are best-in-class, and understanding that each of us is responsible for the quality of everything we do.

Let’s start your next project together; contact us today!