*** ******** ***. *****,*.C.

864-***-**** adwakg@r.postjobfree.com

Rick Batey

Objective

To share my experiences gained within Injection Molding and advance the Injection Molding community.

Injection Molding Training

I first received a Certificate for Paulson Injection Molding Systems training while at Sonoco Products Company in 1991.

I have continued to read and dissect all information concerning Scientific Injection Molding.

I use and perform shear rate studies, gate freeze studies, multi-factorial DOE’s, as well as melt and steel temperature readings to improve and diagnose process issues. I collect machine actual as well to root cause part defects and improve production yields.

I have performed very different types and various methods of injection molding to produce injection molded parts for textiles, medical, consumer and electronic goods as well as Tier 1 Automotive markets. I have experience with 2K injection molding via transfer, rotating platen, and sliding core methods. While at Magna/Innertech we produced back molded, textile over-molded A, B, and C-pillar trim. While at Draexlmaier we injection molded Instrument Panels with the Foamelt (SGI) injection molding process. Utilizing chemical foaming agent and some machine specific upgrades; the injection mold is opened while cooling to allow for increased nominal wall thickness with low deflection and warp at reduced cycle times. We also produced electrical parts with rotating platen, 2k, and insert over-molded nylon bushings. Door panels as well as other assorted interior components were produced at Draexlmaier as well. Plastic Omnium is a worldwide supplier of painted bumper covers and fascias for the Automotive market. Plasman is a Tier 1 Automotive Supplier for Spoilers including those utilizing Lidar and Fascias that are painted and assembled for their customers.

Experience

2022-2023 Plasman Greer, S.C.

Process Engineer of Injection Molding

Hired to address critical issues with Customer and provide long term resolution..

I was responsible for addressing concerns and technical issues of the SQE’s during the total completion of the G09 launch.

I was given the tooling package for customer Volkswagen to launch due to customer concerns over quality and process issues.

Work hand in hand with the Maintenance department to create scrap locations within the small machine enclosures. Robot programs were changed to auto-reject start up parts as well as those produced with actual settings outside machine nominal settings, shutting down the machine after 3 pieces are produced.

Provide robot programming to start using heat guns to remove parting line flash from several TPO and ABS parts. This was very effective in reducing the operators work load and improving part quality for the paint line.

Provide advanced training to the Process Technicians and fellow Process Engineers concerning machine, mold, methods, material, machine and robot (best practices for programming and EOAT builds) including short cuts on the Engel CC300 controller.

Sample and approve 2nd or 3rd machines for better scheduling flexibility and to reduce capacity constraints.

Create new molding machine order standards providing improved efficiency, cycle requirement flexibility, reduced machine foot prints, interface of water temperature units and other downstream equipment. The focus of this exercise was to allow the plant reduced spare part requirements and component storage (pump stacks).

With a host of customer complaints concerning non-fills, I started pushing for adoption of the Plasman standard to install cavity pressure transducers in problem tools and all new tools being built for the plant.

Repurpose a used Keyence camera system for non-fill detection and auto-reject keeping the parts off the conveyor belt and out of reach of the operator.

Due to excessively long pack and hold times, had a sample of CFA delivered to the plant with the intent to internally foam the parts, leading to reduced cavity pressure and parting line flash. Several machines are currently grossly over capacity due to woefully long cycle times.

2021–2022 Plastic Omnium Greer, S.C.

Technical Manager of Injection Molding

Offered promotion to first Management job. Oversaw approximately 20 Technicians and Resin Tech’s plus two Process Engineers.

Responsible for disciplinary issues with the team.

Responsible for scheduling coverage for vacation and FMLA.

Approve Timesheets and Vacation requests.

Responsible for meeting the KPI’s for the department concerning overtime, scrap, OEE, and mold change over times.

2012–2021 Draexlmaier Automotive of America Duncan, S.C.

Senior Process Engineer of IM Technology

Successfully launched in excess of 90 new molds for the electrical division. Parts vary from 2k insert over-molded brackets to Class A+ covers for under the hood.

Successfully completed the implementation of 2D Barcode UV laser marking to aide the customer in ensuring the correct parts are installed on their vehicles.

Utilized new camera technology to ensure only Good parts, with all inserts loaded, and NO flash is present inside the metal inserts.

Built a heated bushing modification station to create a mechanical interlock of PA inserts over-molded with PP 30GF.

Deployed two six-axis robots (Fanuc) to automatically drill vacuum lamination holes in map pockets due to the tool design allowing the holes to close or flash over.

Finish automated assembly project utilizing six-axis Fanuc robot to assemble locking clip onto electrical box lid. Parts were removed from third party containment after successful implementation.

Setup automated vision system inspection of Door Carriers. Lock bezel areas inspected within the current press cycle times.

Configure automated punching system that utilizes a six-axis Fanuc robot to allow the operator to change part punching for LH only, RH only, or BOTH parts to be punched without interrupting production.

Improve cycle time of automated punching operation by allowing gantry robot to complete cycle after handing six-axis robot the final part for punching. Reduction was 35 seconds and reduced capacity issues on 500 ton machine.

Setup automated vision system inspection of co-injected parts confirming only completely formed parts can be deposited onto the conveyor belt.

Convert three difficult to mold part programs to cavity pressure switch-over and avoided continued customer complaints of non-fills.

Change all automation programs to reject first three shots versus first five parts on non-safety critical parts. This reduced start up scrap by 40%.

Assist in creating automation interface standard to allow rapid relocation of downstream automation to back up injection molding machines.

Successful process development of the first SGI injection molded parts within Draexlmaier Automotive. Parts are molded with CFA and allowed to expand an additional 1.8 mm of nominal wall stock.

Develop automation concept to feed airbag nets to a gantry robot for a safety critical Instrument Panel Top Pad.

Modify automation programs to require scan of the Airbag net lot number BEFORE production can be started on safety critical parts.

Modify automation programs to deploy various methods to render laser marked bar codes unreadable to hand help scanners for scrap or rejected parts.

Used various sensors and cameras to reject parts for flash, missing inserts, cosmetic defects (excessive flow lines and etc.) before placing them onto the conveyor belt for the operator to pack.

Integration of flow sensors into the water temperature control units on our older machinery to render them inoperable if minimum water flows and not detected.

Identifying methods to deploy specific water flow and temperature confirmation for multiple molds in various machines.

Studying methods to switch needle grippers for airbag nets from pneumatic actuation to electric stroke controlled I/O Link grippers.

Currently finishing up integration of automated assembly with three screws and one plastic clip with auto-packing of the parts. System will feed empty totes into the robot area and feed full toes out another conveyor belt when the proper pack quantity is reached.

In process of identifying a co-bot supplier and developing a number of opportunities to deploy them and reduce scrap and operator requirements.

2007–2012 Innertech Division of Magna Spartanburg, S.C.

Process Engineer

Process improvements resulting in scrap reductions from a 6.5% to an average of 1.3% or less.

Reduction of cycle times of 35 % on average while still maintaining part form, fit and cosmetic requirements.

Change robot programs to automatically count startup cycles prior to inserting textile into the mold for ‘back molded’ products.

Proved process repeatability and part dimensions using internally generated scrap with a return on investment of 9 months. Cost savings has been calculated at $40,000 per year.

Corrected out of spec dimensions on four molds allowing customer to approve PPAP’s and pay for the outstanding tooling balances.

Present Management with Business model to return out sourced molding within the Company. Cost savings resulted in a minimum savings of $60,000 per year for shipping costs.

Cycle time reductions on the nine formerly out sourced molds averaged 40% over previous quoted times.

Create and stream line Mold Change Work Instructions, resulting in a 35% reduction in change over times.

Write Work Instructions for all areas of the injection molding Business Unit: Start Up and Shut Down, of all injection molding cells; Start Up and Shut Down of all auxiliary molding equipment; Mold PM Instructions; Emergency Water Cooling Instructions; and Injection Molding Tooling Standards.

Create an Injection Molding Machine Spec list for all brands of injection molding machinery. All pertinent machine specs, weight and size limits, machine options installed, number of internal mold heat zones, automation type and payloads and water systems listed for handy reference.

Create ultra sonic knife change procedure to achieve repeatable and stable replacement of trim cell ultra sonic knives.

Program trim cells to count cut cycles, then when required, automatically move six axis robots into the knife inspection/change position.

Program E70 and E71 molds and trim cell programs on both production cells fro increased injection molding capacity and flexibility.

Add air knives to reduce #1 scrap defect (foreign objects on textile class A-surface) to #6 within two weeks time.

Present Management with a cost effective digital camera system for automated detection and rejection of non-fill and ‘flashed’ clip towers.

1998–2007 Seeber USA / Roechling Automotive Duncan, S.C.

Process Engineer

Process improvements resulting in actual cycle time reductions 20-60% faster than quoted, including two components and insert molded parts.

Successfully insert molded level sensors into an expansion bottle with automation.

Modified a robot program to reject start up parts automatically, for an expansion tank process. This reduced the company’s risk of part failure in the field and liability costs.

Solved an insert molding process problem by allowing the robot program to distinguish between inserts loaded into the EOAT, then making the decision to insert the plates or fetch them each time the molding machine is started.

Successfully solved several tooling problems that caused high reject rates due to unacceptable part cosmetics, gate blush, jetting, and molded in stress.

Installed the first Rhytemper pulse cooling system in North America.

Process responsibilities include two component parts; produced with sliding core (tool), transfer over-molding and rotating platten (machine) systems.

Integrate non-fill sensors into automation systems, machine and EOAT mounted. This includes limit switches, laser sensors, and vacuum confirmation.

Review and make improvements to tool designs.

Establish process for production of new tools.

Design and build over 300 End of Arm Tooling for automatic production of parts.

1997-1998 Bavarian Precision Tooling Duncan, S.C.

Process Specialist

Sample all new molds and provide all process documentation required by customer.

Troubleshoot existing tool designs to improve quality and cycle times.

Perform all preventative maintenance on injection molding machine.

1992-1997 More Plastics Spartanburg, S.C.

Shift Supervisor / Process Technician

Set and start all molds for production.

Provide all documentation required for processes and maintain files.

Directly responsible for personnel on shift.

1988-1992 Sonoco Products Company Greenville, S.C.

Assistant Supervisor / Process Technician

Adjust processes to maintain quality product based on SPC.

Set and start molds for production.

Fill in for Supervisor when not present.

1986-1988 Precision Technology Travelers Rest, S.C.

Lead Material Handler

Communicate daily production requirements to balance of the team.

Perform color and material changes on injection molding machines.

Make process adjustments when necessary.

Restart down equipment.

Education

1980–1985 Travelers Rest High School Travelers Rest, S.C.

Received Scholarship to Greenville Technical College.

Graduated with Honors

2014 8D Problem Solving DAA Duncan, S.C.

Received Basic 8D Problem Solving for Customer satisfaction.

2013 PLM Training DAA Duncan, S.C.

Received Basic Siemens PLM training.

2012 Motion Mechanix Duncan, S.C.

Received Certificate in Advanced Fanuc Robot Programming, RJ 3 controller.

2010 Motoman Robots and Automation W. Carrollton, O.H.

Received Certificate in Robot Programming, NX 100 controller.

2009 WJT and Associates Spartanburg, S.C.

Received Certificate in “Advanced Injection Molding Principles”.

2003 Greenville Technical College Greenville, S.C.

Received Certificate in “Mastering Workplace Communications”.

1999 Engel Injection Molding Systems Guelph,Canada

Received Certificate in Automation Programming.

1994 Spartan Plastics Spartanburg, S.C.

Received Certificate in Hydraulic trouble-shooting.

1991 Sonoco Products Company Greenville, S.C.

Received Certificate in Paulson “Injection Molding Technology”.

Received Certificate in SPC training.

Interests

Personal References:

Spending time with friends and family, mainly our grandchildren!

Furnished upon request.

Special Skills

Scientific Injection Molding Principles; Trouble shooting injection molding defects to determine the root cause so long term solutions can be executed; Sequential Valve Gates (pneumatic and hydraulic) controlled via screw position or time, even for two component injection molding; Two component molding by sliding core, rotary table, transfer and insert molding; I have used numerous resins in my career from commodity resins to exotic engineered resins; EOAT construction and interface to various robots; Insert molding including textiles; Kistler Cavity Pressure injection molding; Gantry (Engel, Yushin, Krauss Maffie, Wittmann and Sepro brands) and six-axis robots (Fanuc Advanced Training, Kuka, Motoman and ABB systems); automated part assembly and quality confirmation via robots.

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