Post on 06-May-2015
description
Corporate Overview- Mack Confidential & Proprietary-
WHO WE ARE
Full-service contract manufacturer Specializing in…
Custom injection molding Painting Metal fabrication Machining Assembly
Offering product development resources… Product design Prototyping Engineering services
WHO WE ARE
Founded in 1920 – privately owned & operated Headquartered in Arlington, Vermont Three operating divisions, 10 locations ~1800 employees Annual sales: $260 million No long-term debt, 5A1 D&B rating Certifications
ISO 9001 ISO 13485 (Mack North, Mack Prototype, Mack Technologies) ISO 14001 (Mack South) AS9100 (Mack Technologies) ISO/TS 16949 (Mack South)
FDA Registered (Mack North)
Mack Molding - North Mack
Molding/MackMedical Product Development Plastic Molding Metal Fabrication Paint and Assembly Contract Manufacturing
Mack Prototype
Mack Molding - South Plastic Molding Class A paint Assembly
Mack Technologies Electronics Contract Manufacturing
SMT, Turn-key System Integration, PCB/System Level Test Development
MACKGroup SLA Rapid Prototyping
Fused Deposition Modeling
CNC Machining LIM Cast Urethane Low-volume Injection
Molding & Manufacturing
CORPORATE STRUCTURE
Mack TechnologiesWestford, Massachusetts
Melbourne, FloridaJuarez, Mexico
Mack NorthArlington, Vermont (2)
Cavendish, VermontPownal, Vermont
Mack SouthStatesville, North Carolina
Inman, South Carolina
Mack PrototypeGardner, Massachusetts
LOCATIONS
WHAT WE DO
Contract manufacturing
Product design & development
Rapid prototyping & low volume manufacturing
Custom injection molding
Cleanroom molding
Finishing & assembly
Sheet metal fabrication
Full-service machining
Medical Class II/Class III contract manufacturing
DESIGN & DEVELOPMENT
Application Development Center
Engineering analysis
Supply base selection and management
Material and process selection
Tool design and management
DESIGN & DEVELOPMENT
Interactive feedback with designers
Mechanical design
Design for manufacturing
Moldflow
Finite element analysis
Process selection
MECHANICAL DESIGN
METAL-TO-PLASTIC CONVERSION
Orthopedic Ankle Clamp
INDUSTRIAL & MECHANICAL DESIGN
PART MOLDFLOW
FINITE ELEMENT ANALYSIS
PROTOTYPING/LOW VOLUME MFG
SLA rapid prototyping
Fused deposition modeling (FDM)
CNC machining
LIM cast urethane
Low-volume injection molding (10-230 ton)
Extensive finishing capabilities
CUSTOM INJECTION MOLDING
92 years of expertise
Six facilities Vermont (3) Massachusetts North Carolina South Carolina
120 injection molding machines
28-4000 tons
.6-800 ozs
MOLDING PROCESSES
Injection
Structural foam
Gas counter pressure
Gas-assist (internal & external)
Two-shot molding
In-mold decorating
Overmolding
Insert molding
High temp molding
INJECTION MOLDING
Molten plastic injected into a mold under high pressure
Fast cycles
3-5 ton/sq in clamp required
Lowest part weight
Good surface finish
Low molded-in stress
STRUCTURAL FOAM MOLDING
Molten plastic injected with a chemical blowing agent
Short shot process
Thicker part wall required
Low stress
Slow cycles
¼ - 1 ton/sq in clamp required
Reduces sink issues
Rib-to-wall ratio can be greater
Poor surface finish; lots of swirl
Heavier part weight
GAS COUNTERPRESSURE
Structural foam shot into a pressurized cavity
Improved surface finish over structural foam
Cavity pressure holds out-gassing in check
Slightly heavier part than structural foam
Slightly slower cycle
Higher tool cost & maintenance
INTERNAL GAS-ASSIST
Gas confined within the part
Reduces sink
Reduces stress
Reduces press tonnage required
Longer flow lengths can eliminate need for manifolds
Licensed for any application
EXTERNAL GAS-ASSIST
Gas is pressurized between the core steel and the part
Reduces sink
Reduces stress
Must be confined by using core side part design
TWO-SHOT MOLDING
OVERMOLDING
LARGE PART MOLDING
RESIN PORTFOLIO
FINISHING & ASSEMBLY
Automated
Cleanroom
Heat staking
Testing
Ultrasonic
Laser welding
Inserting
Work cell
RFID tagging
Assembly Decorating
Heat sealing
Heat transferring
Hot stamping
Laser marking
Pad printing
Silk screening
Painting
Decorative
Conductive
Robots
Automated
Overhead lines
Walk-in booths
Class A
CNC machining
Swiss lathes
Integrex turning & machining ctr
14” optical comparator
CAD/CAM
Ultrasonic parts washing
Vibratory tumble
Machining
PREMIUM CLASS ‘A’ PAINT SYSTEM
11,000-sq-ft enclosed HEPA filter environment
1200’ of conveyor supported from underside of parts using 175 paint racks
Ultra high filtration 5-station wash & rinse system
Color changes <5 minutes
3 Fanuc model 250i paint robots
Electrostatic or HVLP
Infrared/convection curing ovens
PREMIUM CLASS ‘A’ PAINT SYSTEM
HEPA filtered air Dust & dirt free environment
Underside part support Reduces scrap generated by
standard overhead systems
5-station wash system Insures clean surfaces
Electrostatic paint system Ransburg rotary atomizer
improves transfer efficiency and final finish quality
Infrared curing ovens Reduce air movement Improve first pass yield
SHEET METAL FABRICATION
State-of-the-art soft-tooled fabrication
Complete laser, punching & forming for NPI & production requirements
Product development focus featuring rapid prototype development
SECONDARY PROCESSING
Vibration deburr
E-series press brake
Haeger insertion equipment
Auto-assist silk screening
Wash line
Automated bead blasting
Wet time-savings equipment
SECONDARY PROCESSING
Welding
Metal finishing
Fastening
SHEET METAL CASE STUDY
Commercial High-tech Blender
86 unique metal parts
Stainless steel construction
Multiple gauge materials
Riveted assembly
Laser cutting/punching
Metal forming
Hardware insertion
SHEET METAL CASE STUDY
Commercial Mail Sorting System
34 unique metal parts
CRS, pre-plated, stainless steel
Thicknesses range from 18-10 gauge
Part size: 2”x2” to 48”x96”
Laser cutting/punching/forming
Tapping
Hardware insertion
Welding: Spot, MIG
Metal finishing
MACHINING
Milling & turning
Small parts
Parts with long length-to-diameter ratios
Complex parts
DONE-IN-ONE MILLING
Mazak Integrex Mark IV
Turning & machining in a single setup
40-tool capacity
Touch probe tool setter
KM63 dual contact tool connection
2” thru-capacity
LNS Servo 65 bar feeder
CITIZEN SWISS LATHES
Two Citizen A20VII lathes
Seven-axes, 20mm machines
21 tools
C-320 bar feeders 3-20 mm barstock
capacity +0.0000”/-0.0005”
precision ground stock
Minimized cycle times via simultaneous main & sub-spindle processes, 32 m/min rapid feed rates
AUXILIARY EQUIPMENT/SOFTWARE
Ultrasonic parts washing
Vibratory tumble deburring
14” optical comparator
Surface finish analyzer
Fully integrated CAD/CAM Part-Maker -- From solid
model to complete 3D simulation to machine G-code (Swiss & Integrex)
MatrixCam – Offline conversation programming (Integrex)
CONTRACT MANUFACTURING
Program management
Global supply management
DFM/DFT
FMEA
Electronic integration & test
Order fulfillment & distribution
PROJECT TEAM
ProgramManager
Supplier Selection /Management
Tooling
Prototyping
Design
Order Fulfillment
ManufacturingServices
Plastic Molded Products
Soft Tool Metal
Product Assembly
Quality & RegulatoryCompliance
Mack TechnologiesWestford, MAMelbourne, FLJuarez, Mexico
Mack NorthArlington, VT (2) Cavendish, VTPownal, VT
Mack SouthStatesville, NC Inman, SC
Mack Prototype
Gardner, MA
MARKETS WE SERVE
Medical Devices Disposables Instrumentation
Transportation Heavy truck parts Recreation/utility vehicles
Computer & business equipment
Consumer
Defense/aerospace
Energy Batteries Solar-powered products Fuel cell technology
Industrial Structural HVAC Furniture & seating Industrial & building
supplies Lawn & garden
CLEANROOM MOLDING
Class 100,000 molding cleanroom
Installation complete, 12/11
Dedicated to reusable & disposable medical applications
46’ x 44’ modular design Removable panels to allow
for future expansion Dual air-lock doors, 8’ wide
Rapid roll-up doors Ease of product flow, tool
changes
CLEANROOM PRESSES
Six Toshiba 110-ton electric presses
60% less energy consumption than hydraulic
High-precision machines Outfitted with high
pressure water controllers More versatility in resin
selection
ENVIRONMENTAL MONITORING
Gowns/personal protective equipment required
Particulate airborne monitoring according to ISO 14644-1 standard
Particulate control plan includes: Alert level Action level
Ensure compliance with GMPs
WHITEROOM PRESSES
Currently operational Adjacent to new Class
100,000 molding cleanroom
Engel hydraulic presses Low-volume, multi-
color products requiring quick resin/tool changes
24-hour operation for orthopedic trials, medical disposables
CLEANROOM ASSEMBLY
Class 100,000 cleanroom assembly
30’ x 70’ Non-sterile packaging
for medical disposables Light sonic weld
assembly Temperature &
humidity-controlled functional testing
CONTRACT MANUFACTURING
Project management
Supply management
Regulatory compliance
DHF/DMR/DHR management
Design verification
Process validation
Training
DFM/DFT
Order fulfillment/distribution
QUALITY ASSURANCE CONTROL
Quality system 21 CFR 11 & 820 compliant Electronic DMR & DHR
retention
Advanced product quality planning Process flow diagrams Risk assessment/pFMEA Control plans Dynamic control plans
QUALITY ASSURANCE CONTROL
Component & process qualification/validation PPAP IQ/OQ/PQ Reqs traceability/supplier
change controls Config controls/validated
software
Measurement systems CMMs (3) Optical systems (4) NIST-traceable calibration Gage R&R Minitab & DataMite
Post-prod risk assessment
Advanced product quality planning
Process flow diagrams
Risk assessment/pFMEA
Control plans
Dynamic control plans
Supply management
Regulatory compliance
DHF/DMR/DHR management
Design verification
Process validation
Training
DFM/DFT
Order fulfillment/distribution
DEVICES
Class II/Class III PMA products
FDA registered
Clean room molding & assembly
White room molding
Complaint investigation
Obsolescence management
FRU/kitting
CASE & TRAY SYSTEMS
Custom designs based on OEM requirements
Validated manufacturing process
Plastic, stainless steel, titanium & aluminum
Laser welding Hermetically sealed weld bead Free of gas, air, contaminants
JIT stocking arrangements with full lot code
Complete kitting and ship-to distribution services
INSTRUMENTATION
Soft-touch ergonomic handles
Disposable & reusable
Material analysis Lipid resistant resins Gamma stable resins Anti-microbial resins Autoclaveable ergonomic
resins
Overmolding Insert molding Final assembly
CASE STUDY
Therapeutic Device, Photopheresis
Class III PMA device
1,921 total components
616 unique components/80 suppliers
49 subassemblies
Dedicated work cell
Dedicated product support team
8 functional tests
CASE STUDY
Therapeutic Device, Photopheresis
Class III PMA device
1,400 total components
358 custom parts/65 suppliers
18 subassemblies
Component qualification
Dedicated work cell
Dedicated product support team
10 functional tests
TRANSPORTATION
ENERGY
COMPUTER & BUSINESS EQUIPMENT
CONSUMER
INDUSTRIAL
Thank You!Copyright © 2011 Mack. All Rights Reserved.