Last year, GMN Plastics adopted a new employee training system known as Paulson training. For the past year, every employee at GMN Plastics has used the program and it has now been implemented as one of the first steps of new hire job training.
The program has been very effective in helping employees understand basic safety on the molding floor, common manufacturing problems and how to overcome them. The Paulson training has educated our employees with extensive industry specific vocabulary as well. Employees need to pass the training before they can operate machinery to produce parts and this is a good way to identify when people are ready to handle the equipment and begin production work. This training is very important because it has been found to lower product defects and boost overall quality which is a key standard at GMN Plastics.
There is a huge opportunity to grow with this program as the GMN Plastics business builds. The system has helped support the growth at GMN Plastics as more employees are hired and more shifts are added to production.
Dan Thurmond, President of GMN Plastics, has been working in the plastics industry for his entire career and at GMN Plastics for the past 30 years beginning when he started the business. Dan’s plastic experience began in high school when he took a plastics course and continued after graduation at the LA Trade Technical College where he studied plastics manufacturing. During this time he was involved with The Society of Plastic Engineers, a group he is still a member of today, and had his first apprenticeship with an affiliate company in 1969.
How did Dan go from an apprenticeship to starting his own business? He worked his way up through the plastics industry and eventually started two different plastics manufacturing companies. Dan started his first business, T&T Plastic Molding, in California and built it up before selling it four years later. He then moved to the Pacific Northwest where he began working at View-Master, the producer of stereoscopic children’s toys, where he gained experience running the molding, painting, and tooling operations there.
In 1985, Dan started Danegon Plastics with Egon Steinborn in Oregon. As the business grew, they eventually began working with GM Nameplate (GMN). GMN had been looking for a plastic injection molder as it transitioned from all sheet stock materials to injection molded nameplates that would snap into housing components. After a year and a half working as a subcontractor, GMN bought Danegon Plastics in 1995. From there, Danegon Plastics became GMN Oregon and was eventually rebranded as GMN Plastics, the name it currently holds today. While Dan stayed at the company, Egon Steinborn decided to sell his share of the company and went on to own a tool shop that continues to work with Elite Plastics today.
Dan agreed to stay at GMN Plastics for three years to ensure that the company was up and running. After working with GMN, he decided that there was, and still is, no better place to work and has been here ever since.
Chris Passanante, GMN’s product line manager of plastics, explains that, “Dan is a wonderful person, his compassion and family values carry over to relationships with his employees. He has a wealth of industry knowledge and experience, always open to suggestions and values all of his teams input. I have been very fortunate to be part of Dan’s team for the last 14 years; he has been a great mentor and friend.”
Dan Thurmond is a huge contributor to the success of GMN Plastics and GMN as a whole. He has grown the business as technologies have evolved over time and brings a positive experience to everyone who has the opportunity to work with him. We want to thank Dan for 30 years of commitment to GMN Plastics.
This January we celebrate 20 years since GM Nameplate (GMN) acquired its plastic division. In 1995, GMN bought Danegon Plastics, which became GMN Oregon and was eventually rebranded as GMN Plastics, the current business name.
Danegon Plastics was started in 1985 by Dan Thurmond, current GMN Plastics president, and Egon Steinborn. Before GMN bought Danegon Plastics, the business was run inside of a barn, two horse stalls, and two storage containers with a makeshift roof built in between. When this space had grown too small for the business, Thurmond purchased a large army tent to expand into. As the business grew, Danegon Plastics began to supply GMN with injection molded nameplates as a plastic injection molder. GMN bought Danegon Plastics 10 years after the business was started, in 1995, after working with the company for a year and a half. When GMN bought the business it was moved into a new facility where GMN Plastics currently resides today.
Danegon Plastics had been producing its own line of standard plastic lids for a variety of customers. As the marketplace changed to custom products Danegon Plastics needed to shift with the trend. Dan knew that Danegon Plastics had grown as much as it could on its own and by joining GMN, the business was able to expand to all that it is now. As Dan says, “a business can’t stay at the same level, it needs to grow and for us, GMN was the next big growth opportunity. It took us in a whole new direction. We had previously focused on plastic screw lids, and with GMN we began to focus on nameplates and branding.”
GMN had the resources that Danegon Plastics needed including a wide range of nameplate capabilities and key contacts in large US companies. Danegon Plastics had the plastic molding capabilities that GMN needed as well. By coming together, the two companies were able to grow together with complementary technologies. This shift helped GMN Plastics expand into other areas of plastic injection molding including plastic decorating, thermoforming, welding, and much more.
GMN Plastics has come a long way since it operated out of a storage facility in the 1980’s. Today, GMN Plastics is recognized as a leader in servicing highly regulated industries with comprehensive injection and compression molded products, sub-assemblies, highly decorated parts, and plastic machining. With a 60,000 square foot state-of-the-art facility, GMN Plastics serves the medical, automotive, aerospace, and industrial industries. After 20 years, we have grown to 150 employees and continue to expand year after year. At GMN Plastics we are proud of our history and continued growth.
Two new ultrasonic welding machines have been added to the equipment list in the GMN Plastics facility. Ultrasonic welding is a process in which sound vibration is used to adhere an insert to plastic or plastic to plastic. This technology has many advantages over other processes and is typically chosen because it is more precise, has faster cycle times, is easier to set-up for production, the tooling involved is less expensive, the machines are smaller, and it can be done either as a standalone operation or at the molding machine during the molding process.
Because ultrasonic welding is used for a wide variety of applications, there are many variables to consider when determining whether this technology should be chosen. To decide whether ultrasonic welding is the right option for a project, the team at GMN Plastics looks at factors of the part design including part function, material, cosmetic requirements, and part size.
A good example of the advanced capabilities of ultrasonic welding can be seen through a plastic bezel that GMN Plastics manufactured for a large medical technology corporation. This complex piece used four different inserting operations, each with different heights and locations. Ultrasonic welding was able to meet the customer’s project requirements with reduced set-up times, reduced handling and movement, one piece flow operation (also known as lean manufacturing), and better quality.
When Toyota and their tier one supplier needed a gear shift indicator to match the sleek interior of their Camry line of vehicles, GMN stepped in. It was decided that the piece would be a glossy shade of piano black with a backlighting solution. A difficult combination to achieve, GMN’s plastic division GMN Plastics, was able to provide Toyota with an ideal solution through an extensive painting system and laser etching technology.
Learn more about this ongoing program for Toyota in our case study here.
To watch how this part was made, click play on the video below.
Tonight Dan Thurmond, president of GMN Plastics, won the Lifetime Achievement Award from the Society of Plastics Engineers (SPE) of the Columbia River section. This award is presented to individuals who have gone above and beyond to support and contribute to the plastics community. Beginning in 1996, the Lifetime Achievement Award has honored many members of the industry from injection molders to key suppliers. The SPE, the largest plastics professional society in the world, aims to spread scientific and engineering knowledge of the plastics industry.
For his entire career, Dan Thurmond has been working in the plastics industry. In 1985, Dan and his business partner, Egon Steinborn, started a plastic injection molding company called Danegon and 10 years later, the business was purchased by GM Nameplate (GMN). While Dan stayed on to run GMN’s new plastic division, Egon Steinborn decided to focus on his tooling business instead and continues to do business with GMN Plastics today. Along with Dan, Egon Steinborn, was also awarded the Lifetime Achievement Award.
Bruce Cleckley, CEO of GMN, said of the award, “We are so happy the Columbia River SPE is recognizing Dan’s contribution in acknowledgement of his decades of work in the plastics industry. Dan is an outstanding example of executive leadership and an invaluable member of our team. This Lifetime Achievement award is well deserved. We are pleased the association has noticed what we experience from Dan each day.”
Dan Thurmond is an irreplaceable member of GMN and his contributions to the plastics industry throughout his career have been countless.
In the past year, GMN Plastics has added three new injection molding machines to its equipment list in Beaverton, Oregon. As a plastic molder, this new equipment is essential to provide our customers with the capabilities needed to manufacture their parts. These new machines, one 55 ton machine and two 220 ton machines, are upgraded with new technology and are equipped with tighter tolerances to produce more consistent parts.
This equipment was ordered to specifically meet GMN Plastics specifications so that we can continue to serve our customers to our best ability. Injection molding is a core capability of GMN Plastics and leveraging new state-of-the-art machinery allows us to provide greater precision and better parts.
As our business grows, GMN Plastics is building on our current capabilities to offer more advanced technologies. Plans are in motion to invest in over four new machines in the next year to continue evolving our processes and updating machinery to meet customer project needs.
GMN Plastics, the plastics division of GM Nameplate (GMN), participated in National Manufacturing Day today by hosting 40 students from a local high school. National Manufacturing Day is put on by the Fabricators & Manufacturers Association, International, the National Association of Manufacturers, and the Manufacturing Extension Partnership. The day is meant to build public awareness of manufacturing careers and to underscore the large role that the industry plays in the U.S. economy. There are many preconceived notions about manufacturing and MFG Day attempts to show that it is a very technical industry where skills are learned on the job rather than in a university classroom.
Renee Wakeen, HR Manager of GMN Plastics, described the day as, “a great opportunity to connect with the community and share insight into the plastics manufacturing industry.”
The event consisted of a plant tour which allowed students to see facility operations. While in the plant, students participated in a hands-on activity that allowed them to interact with the plastic manufacturing processes. Students were able to take part in building their own whistles, a project that allowed them to see the lifecycle of a part from molding to decorating to final assembly. Each student left with a whistle that they had helped make themselves.
Students learned about job training, skills needed for manufacturing positions, and career opportunities within the industry. GMN Plastics was happy to host the students for a successful Manufacturing Day event.
During project planning it is very important to ensure that each of the parts will be produced consistently. To do this, the manufacturing process must be qualified to ensure that it is repeatable and stable, both dimensionally and cosmetically. At GMN Plastics, this qualification process is broken down into four sections including design qualification, installation qualification, operational qualification and performance qualification. We will explain them in further detail below:
Design qualification (DQ) - During this initial stage, GMN Plastics receives the design print and goes through a tolerance review to determine whether the tool can be built as the customer has requested.
Installation qualification (IQ) - The GMN Plastics team then begins qualifying how to install the tool so that the process can be repeated in the same way during future production runs.
Operational qualification (OQ) - At this point, design experiments are conducted and variables are tested to identify where the part is best suited to run. To do this, parts are taken from multiple conditions and are submitted to metrology for measurements. Based on the measurement results, the next step is performance qualification.
Performance qualification (PQ) - Finally, features, dimensions and cosmetics are evaluated. The production process is run and a predetermined number of parts are randomly selected and inspected by metrology to measure whether the process is deemed to be both repeatable and reliable.
One strength of GMN Plastics is the high quality standards that are adhered to. To uphold these standards, our team goes through this series of qualification steps for every project to ensure that parts meet our customer’s needs.
In a complex manufacturing industry, it is important to have a set of unique terminology to understand industry-wide common practices. Basic terminology in the plastics industry is provided by the Society of the Plastics Industry Cosmetic Specification of Injection Molded Parts to give manufacturers, suppliers and customers a common language to communicate through.
As a plastics manufacturer, GMN Plastics has a long list of unique vocabulary, so we’ve compiled some of the most common tooling terms used when discussing projects with our customers here:
Taking a tool down: A common process of performing maintenance on a tool
Venting a tool: Creating an opening in the cavity so that gasses can escape while material is being injected into the tool
Inserting a tool: This occurs when a damaged section of steel is replaced for repair or when multiple versions are slightly different
Tool crash: Like a car crash, this can happen in both major and minor incidents, but it means a tool has been damaged
Qualifying a tool: Establishing a manufacturing process that is both repeatable and stable