Category Archive: American manufacturing
Across industries, manufacturers are seeking new ways to optimize product performance while minimizing costs and maximizing production efficiency. In the automotive market, specifically, many companies are now using engineered plastic parts rather than traditional sheet metal.
Shifting from metal to plastic stamping material is not a new concept in the automotive industry, having been employed since the 1950s; yet in recent decades, automakers have been learning more about the benefits of advanced plastics and discovering new, innovative ways to implement them.
Rising Popularity of Plastic Components
From thermoformed exterior cladding to injection molded panel components, plastics are becoming increasingly popular — and with good reason. Here are some benefits to making the switch:
- Lower part cost — Plastic parts are not only more cost-effective to produce than metal, but their lighter weight also makes them less expensive to ship. Secondary processes such as texturing and coloring can also be eliminated and replaced by a single injection molded part. Overall, companies switching to plastics can expect to save 25-50% on part production costs.
- Increased product life — Plastic parts present a much lower risk of corrosion. Unlike metal, plastic does not rust, and most kinds have increased chemical resistance or made from high heat-resistant plastic, making them less susceptible to environmental stresses.
- Lower vehicle weight — While reduced part weight saves money on production and transportation costs, it also decreases emissions and improves fuel economy, allowing automakers to more easily meet sustainability standards.
- Increased strength — In addition to enhanced resistance, many plastic pieces have a higher tensile strength than their metal counterparts. By selecting engineer-grade materials and molding them into an optimized structural design, plastic parts can actually be made stronger than metal.
- Production efficiency — By using versatile methods such as plastic thermoforming and injection molding, many secondary manufacturing processes can be eliminated altogether, saving manufacturers both time and money. Additionally, these processes are more sustainable, as excess plastic can be easily
reground for reuse.
Switch from Metal to Plastic with New Process Fibre
New Process Fibre is a leader in versatile, nonmetal stamped components, including nylon washers ideal for use in automotive applications. As a family-owned company since 1927, we’re committed to providing our customers the best services in the industry. We offer extruding, stamping, and regrinding capabilities, and can run small prototype runs and large multimillion-piece orders alike. All of our work is done in-house.
If you’re ready to make the switch from metal to plastic in your next project, contact us today to learn more.
New Process engineers and technicians received a call from a company in Texas with whom we had never worked. This company was in a tight spot and asked if we could deliver 100,000 specialized non-metallic washers – by the next morning.
The company manufactures compressors used in all of the major HVAC industry players’ products. They usually manufacture their washers in-house, but in this case they needed very tight tolerances that their equipment could not meet. The company asked us to manufacture PTFE washers with a 0.022” thickness and a +/- .002 tolerance.
Meeting the client’s request under such a tight deadline was a challenge, but was possible because of New Process’ material inventory and state-of-the-art machining capabilities. We had the right PTFE material on hand, but did not have the right die to meet the company’s dimensional requirements. We gathered our tooling department experts together and asked if they could stay late that night to build a new die based on the client’s specific needs.
Our experts rallied together to produce a new die in record time. With the right tooling in place, we were able to start the manufacturing process right away. As soon as the job was finished, we shipped them to the client and they received their custom-made washers the next day. Upon receiving the parts, we received a phone call from the client, telling us that they had not seen such a clean machining of washers in years, and they needed 10 million more!
Years later, New Process continues to work with this client, making 3 to 4 million parts for them annually.
New Process is here to help with your next project
New Process is a leading manufacturer of non-metallic stamped parts, specifically PTFE and Nylon washers. As this project demonstrates, our team goes above and beyond to get every job done no matter the product specifications or deadline requirements. Our clients value our expertise and work ethic, and consistently rely on us for follow-up projects.
Want to learn more?
Click here to contact us and to discuss how we can help you with your next project.
At New Process Fibre our facility was recently visited by Sen. Chris Coons as he toured Kent and Sussex counties to speak to manufacturers about their companies, future workers, STEM education, and lean manufacturing. This visit coincides with the senator’s manufacturing bill which he hopes will bring together bipartisan support for legislation that will help manufacturers expand operation and create jobs. Additionally this bill would designate 25 universities as “Manufacturing Universities” which would receive federal money to help align their coursework to meet the needs of the manufacturing sector and help train the next generation of engineers and skilled workers.
As a business that was founded in 1927 we are always looking to improve our company. We have not only increased our product offerings but have improved our processes to ensure our customers always receive a quality product. We pride ourselves on our in-house manufacturing capabilities which allow us to perform every step of the process and fabricate our own tooling to manufacture simple and complex non-metallic components. We’ll continue to follow the senator’s bill and keep our readers informed about improving the manufacturing sector. To stay up-to-date on the manufacturing industry you can follow New Process Fibre on Twitter and LinkedIn and to learn more about our company and commitment to quality visit our website.
It seems each month this year we have heard news of the economy recovering and more and more American manufacturers are experiencing growth. Recently, the Federal Reserve reported that industrial production continued to increase in June marking one of the strongest quarters in almost four years.
These reports point out that the increase in manufacturing output points to a recovering economy but there are other reasons behind the increase in American-made products. One is the increase in wages abroad. For many years cheap labor was available in other countries like China, but now their wages are rising.
Additionally, our world now moves at a faster pace and many companies want a quick turnaround on products. Choosing an American company can help customers decrease their lead time and receive faster shipping. However, if a customer chooses a company located abroad the cost might be higher to receive the product quickly.
At New Process Fibre we are proud to be a Made in the USA company and all our products are fabricated in-house which allows us to reduce our production cycle time for quick turnaround. To learn more about non-metallic stamped components, visit our website. Our company is also active on Twitter and LinkedIn where we post more industry news.
At New Process Fibre quality is very important to us. We recently underwent a rigorous ISO recertification audit and are excited to announce to our readers that our results were very positive. SAI Global conducted the audit and spent two full days at our facility to review our processes. The auditor thoroughly reviewed each aspect of our business from our processes from management review, to quoting, to production and inventory and everything in between. It was noted on several occasions that we have a very good system in place at New Process Fibre. We were given a few places to improve and we look forward to working on these aspects to help our employees grow individually and our company to grow as an organization to improve our quality management system.
We’d also like to thank each of our employees who helped us through the audit. There was a lot of work we put in leading up and during the audit. We appreciated the attentiveness during the audit and of course are happy that we continue with these high quality processes everyday to ensure that our products meet or exceed our customers’ expectations.
To learn more about New Process Fibre and our commitment to quality, visit our website.
It’s been a rough ride for the economy this year. While things stand a chance of improving in 2013 (simply because market downturns always eventually recover from their slumps), the future of the nation’s economy remains uncertain. One could, of course, just stand by the wayside, fold one’s arms across one’s chest, and remain a passive spectator to events as they play out during the next business year. But that’s not how we roll at New Process Fibre. On the contrary, when the going gets rough and the terrain gets unfamiliar, that’s exactly the moment we roll up our sleeves and say to ourselves, “How can we make this a better situation?”
The American economy is still the largest in the world (unless one counts the entire E.U). Our manufacturing sector still surpasses any other country on Earth (though China is a close and worthy contender in terms of production output). But there are always ways of shoring up something to make it that much stronger.
So while the politicians and talking heads wrangle back and forth in Washington about “fiscal cliffs”, etc., we thought we’d take another, simple, more direct approach to addressing the economic situation: buy American before and after Christmas. It’s been estimated that if every American family were to spend a minimum of $64 on American-made products for the holiday season, some 200,000 new jobs could be created. Now granted, many of these jobs would be temporary holiday jobs in retail and packaging/shipping. That being said, if there was a consistent and overwhelming demand for American-made goods this December and early January, things would be looking up for a lot of hard-pressed, hard-working folks in the manufacturing sector. In short, it might well be some medicine this country needs.
It’s not like we’re seers gazing into crystal balls here. We’re a company that deals with realities: we confront real problems with real solutions. And for our money, this is as good a short-run solution to jumpstarting our economy in the right direction that we’re able to see. Leave the politics to the politicians. Let Americans help Americans.