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Plastics Processing: A Changing Environment: Jack Avery GE Plastics ANTEC 2004 May 18, 2004

This document summarizes trends in the plastics processing industry and provides a look into the future. It discusses how economic changes, globalization, and increased competition are driving trends towards consolidation, outsourcing, and new materials and processes. Emerging technologies like multi-material molding, in-mold decorating, and plastic-metal hybrid processes are allowing processors to provide more value through improved performance, lower costs, and quicker product changes. To succeed in the future, processors will need to focus on innovation, manufacturing cells, and adding value through services like complete module assembly.

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Hans Michael
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38 views30 pages

Plastics Processing: A Changing Environment: Jack Avery GE Plastics ANTEC 2004 May 18, 2004

This document summarizes trends in the plastics processing industry and provides a look into the future. It discusses how economic changes, globalization, and increased competition are driving trends towards consolidation, outsourcing, and new materials and processes. Emerging technologies like multi-material molding, in-mold decorating, and plastic-metal hybrid processes are allowing processors to provide more value through improved performance, lower costs, and quicker product changes. To succeed in the future, processors will need to focus on innovation, manufacturing cells, and adding value through services like complete module assembly.

Uploaded by

Hans Michael
Copyright
© Attribution Non-Commercial (BY-NC)
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PPT, PDF, TXT or read online on Scribd
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Plastics Processing:

A Changing Environment

Jack Avery
GE Plastics
ANTEC 2004
May 18, 2004
Managing Change in the Plastics Industry

 Trends
 Materials
 Processes
 Machines
 Competition
 A Look at the Future
Trends
Trends
N. American Economic Changes: 2000 – 2004

• 2000 Dot Com Bubble Burst


• Recession
• Terrorism/Global Uncertainty
• Corporate Consolidation
• Globalization
• Accelerated Change: Domestic/International Focus

It’s A Whole New Ballgame!!


Materials
Plastics – 21st Century
Materials
 Metals have been know for 5000 years

 Synthetic polymers have been known for 80 years

 Products must meet ever higher performance standards

 “21st Century” Engineering materials must prove their


mettle with respect to competition

 Cost is everybody’s concern in order to maintain profitability

Expect Changes
Business Climate Materials
 Changing business climate
- Globalization
- High investor expectations
- Competition

 Companies’ response
–Reorganizations, restructuring, mergers
–De-structuring
–Divestitures/acquisitions
–Joint Venturing/resource pooling
–“Refocusing” R&D

 Specialized vs. diversified portfolios


 Oil/Natural Gas Pricing
- Material prices
- Product prices
 Customer pricing pressures

Materials Business is Undergoing Constant Change


Materials
 Metallocenes
– Higher Performance vs Traditional Olefins
– Infrastructure

 Blends/Alloys of Existing Materials: Tailor Performance


 Fillers: Increase Strength & Stiffness
 Nanocomposites (Nanometer-sized clay particles)
–Small amounts provide significant improvements in
thermal and mechanical properties
–W/o significantly raising density
 Recycling: Value equation

• Materials Tailored to Meet Performance Requirements


• Full Property Utilization Must Be Realized in Application Performance
Processes
Multi-Material Molding Processing
Multi-Material Molding Provides a Wide Range of
Performance Options Through the Combination of
Different Materials
 Aesthetic Surface + Strength

 Soft touch + Strength


 Aesthetic Surface + Regrind
 Functionality

Performance
 Cost

Optimize Performance in the Molding Operation


without Additional Handling & Secondary Operations
Multi-Material Molding Processing

Multi-material Geographic Utilization

25% 10%

65%

• Europe leads in multi-material processing


• N. America & Asia utilization growing
Multi-Material Molding
Machine Options Mold Options

• Rotating mold plate


• Rotating center plate
• Cavity transfer
• Rotating machine platen
• Sliding core
• Highly flexible
• Wide range of options
Multi-Material Molding
Co-Injection Molding
Multi-Material Molding
“Over-Molding”/Two-Component Molding
In-Mold Decorating Processing
Cellphones  Part is Decorated During
the Molding Cycle
Advantages
 Design Flexibility
– Product Differentiation
– Quick Changeover
– Complex Parts
Can Be Decorated
 Manufacturing Productivity
– Processing and Labor
Costs Reduced
– Secondary Operations
Can be Reduced

• Quick Product Change Over and Product Differentiation


Capability Drive In-Mold Decorating Growth
Considerations
Multi-Material Molding
Process Selection Criteria

• What benefits will multi-material processing provide?


- Performance
- Material cost
• Will it provide value?
- Machine cost & tool cost
- Cost of handling & assembly
• Design considerations

• Understand customer requirements


• Bring all parties together early
Considerations
Multi-Material Molding

Material Adhesion

• Desirable?
• Material compatibility
• Mechanical adhesion
• Mechanical interlock
• Material Suppliers input
In-Mold Decorating

SMART Roadster Roof Module


• LEXAN SLX: No painting/clear-coat
• Co-extruded color layer & clear cap
• Excellent gloss & color retention
• Good scratch & mar resistance
• Quick color change-over
Plastic-Metal Technology Processing
“Hybrid” Process*:
1. Deep-Drawn, Perforated Sheet-Metal Part Inserted into Injection Mold
2. Plastic Melt Passes through Punched Opening in Sheet Metal
3. "Rivet Head" Formed Between Mold Cavity Wall and the Inserted
Metal Part
 Cost-Effective Production Methods
– Steel Stamping
– Injection Molding
 Complimentary Properties
– Highly Loadable,
Strong Connection

Bayer
Injection Molding Machine of 20?? Machines
 Enhanced Process Capability
 "Global" Communications Capability
–Information Acquisition/Transfer via Network
–Remote Monitoring/Adjustment
–Remote Diagnostics/Service
 Increased Functionality
–Manifold Control
–Multiple Processes
–Robotics

 Enhanced Productivity
–Modular
–Smaller Footprint
–More Efficient

Injection Molding Machine Will Be the "Command Center" for Manufacturing Cells
Future
Future

• Industry has changed!


Trends Impacting Molders Future
 Consolidation
 Globalization

 Product Complexity
 Product Development Lead Time/ Costs
 Product Manufacturing Companies
 Productivity
 Quality

 Cost/Price/Profitability
• Issues: - OEM Pressures: Price, Quality and Co-location
- Sufficient Profitability for Reinvestment
Injection Molding Processes
Future

 Process Integration
– Gas-Assist Injection Molding
– Co-Injection & Gas-Assist Injection Molding
– Multi-Component Molding
– In-Mold Decorating
– Plastic-Metal Technology
 Specialized Processes
–Injection Molding and Compounding (IMC)
–Micromolding
 Manufacturing Cells

Hybrid Molding Technologies Utilizing Strengths of Each Process


is the Key to Capitalizing on Opportunities to Provide Customer Value
"Manufacturing Cell" Future

 Multiple Operations Completed Within a Single System


to Produce a "Finished" Assembly or Product
– System Consists of Multiple Operations
– Value Added at Each Step

 Auto Bumper
- Injection Mold Bumper
- Co-Injection Mold Lens and Seal into Opening

 DVD Manufacture
- Molding
- Metallization
- Bonding of Two Discs
- Lacquering
In-Mold Decorating
Large Part IMD Process

Drying Forming Trimmin


g

Insert Injection Finished


Film Molding Part
In-Mold Decoration

Industrialization Cell at GE Plastics

FILM THERMOFORMER LASER TRIMMER INJECTION MOLDING


65” x 55” Tool Capability 2700 Ton Capability
Adding Customer Value Future
 Joint Ventures
- Auto: Complete Front-end Modules
- Hella: Lighting
- Behr Gmbh & Co: Vehicle A/C and Engine Cooling Systems
- Plastics Omnium: Exterior Body & Modules

 Markets having Large Parts or with Stringent Requirements


- Agriculture/Rec. & Leisure: Large parts difficult to ship
- Medical devices: Quality & Compliance

 Niche Market
- Fits your companie’s expertise
- Large parts/low volumes
- Medical
Processor Opportunity Future

Keys to Prosperity:

1. Recognize reality of today’s economy


2. Redefine our business
3. Focus on providing value
4. Compete on innovation, not cost

“New Norm”
Managing Change
Future

Change is Inevitable

Progress is Optional

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