Matthew Key, Director of Program ManagementThomson Plastics, Inc. (TPI), a manufacturing firm, has an extensive press capability ranging from 200 to an impressive 3,700 tons of clamp force. This wide range allows TPI to specialize in producing medium and large-sized components precisely. With approximately 30 percent of its machine fleet exceeding 1000 tons, the company solidifies its position as a key player in the plastic injection molding industry. Its innovative processes seamlessly integrate design complexity with reliable production methods. Guiding clients’ products from conception to production, TPI ensures timely project delivery while upholding exacting quality standards.
“Our goal is to become the largest tonnage molder in the southeast United States,” says Matthew Key, director of program management.
Understanding the customer’s vision and design from the earliest stages, even when it’s just a concept on paper, is central to TPI’s approach. This understanding guides the entire launch process, known as Advanced Product Quality Planning (APQP), broken down into five comprehensive chapters. These chapters ensure meticulous attention to design, validation and preparation for production.
Chapter zero, the quoting phase, involves program managers and the engineering team evaluating project requirements and parameters. This understanding carries forward to chapter one, the product award phase. Chapter two entails close collaboration with the customer for product design. Chapter three focuses on process design and development, while chapter four is dedicated to product and process verification, ensuring readiness for production. Finally, the last chapter marks the handover to production, signifying a seamless transition from new development to everyday production operations.
Within program management, strict adherence to AIAG guidelines is the cornerstone of operations. Internally, the team employs a customer satisfaction gauge, rated from zero to five, to strategically allocate resources and identify areas for improvement, promptly addressing customers’ precise requirements.
A hallmark of TPI is providing immediate support to clients facing issues during the launch of a new application or when embarking on the development of a new product design. Due to the trust established, clients often seek TPI’s recommendations before finalizing their designs. They acknowledge the expertise and value of its engineering team, along with its willingness to learn alongside them throughout the process. Through this collaborative approach, it has contributed to the development of many new products.
Our goal is to become the largest tonnage molder in the southeast United States
Currently, TPI is engaged in developing a new design for a large-scale product that encompasses multiple tools and components for an automotive company. Its collaboration with the customer is built on a foundation of trust, allowing it to play a pivotal role in shaping various aspects of the design of the vehicle, including its appearance, functionality, material and grain selection. Since the inception of the project, the team has been involved in the general design concept, working closely with the customer to ensure that the final product meets their requirements.
Following a recent facility upgrade, it has made substantial investments in 16 new injection molding machines. Leveraging advanced equipment and in-depth understanding of specific processes and customer applications, the team has ramped up machine output to meet clients’ increasing demands.
With its large tonnage capabilities and commitment to customer satisfaction, TPI has solidified its position as a trusted partner, delivering unmatched product excellence to clients.
