Wednesday, June 25th, 2014
By Mike Verespej, SPI Correspondent
You could fill a book with the long laundry list of accomplishments that led to injection-molding company Plastic Molding Technology Inc. being chosen in March as the 2014 small company Manufacturer of the Year by the Manufacturing Leadership Council. In its 10th year, Frost & Sullivan’s Manufacturing Leadership Council honors companies and individuals that are shaping the future of global manufacturing.
And while certainly proud of what the $10 million El Paso, Texas, company with 100 employees has accomplished, CEO Charles A. Sholtis is even prouder of what the award says about his workforce.
“The award speaks volumes about the caliber of our management team, the workforce we have, and what they’ve accomplished the last three years in streamlining processes, identifying areas for waste and cost reduction and finding ways to be more sustainable,” Sholtis said. “It says a lot about their ability to take on large projects as a team and make the company more profitable through operational excellence.”
Indeed, despite escalating raw material prices and the economic crash in late 2008, PMT achieved record revenue and earnings in fiscal years 2010 through 2013.
“You are only as good as your people. Without them, we wouldn’t be the success story we are,” said Sholtis. “These honors simply reinforce that the plastics industry is at the forefront of best practices in manufacturing.”
Here are just some of PMT’s achievements the last three years:
- Savings of 1.8 million kilowatt hours (kWh) of energy per year, half of them from a grinder control system developed in-house that has reduced energy consumption on the company’s 40 plastics grinders by 95 percent or nearly 900,000 kWh annually.
- Eighteen all-electric presses added since 2010—part of a $2.9 million investment in equipment and automation—have cut energy consumption by almost 400,000 kWh annually.
- Plant-wide efficiency has improved to 96 percent, and on-time deliveries have risen to 98 percent.
- Production scrap was reduced by more than 50 percent in the first year of a program to cut waste. The company also reduced its use of virgin resins by 380,000 pounds annually by blending in plastic regrind and using recycled resin.
- A new mold storage system has saved an estimated 780 man-hours per year and sped up the mold setting process, and a new overhead crane system for mold handling has saved an estimated 250 man-hours annually.
- A standalone mold service bench with a gantry crane on the production floor has reduced the time needed for routine cleanings, saving another 420 man-hours per year.
Frost & Sullivan’s Manufacturing Leadership Council in March honored 100 world-class manufacturing companies and individual leaders as winners of the 2014 Manufacturing Leadership Awards (ML Awards). According to the Council, recipients of the ML Awards have distinguished themselves by embracing breakthrough innovation and enabling their companies to anticipate and respond to customers with unmatched agility.