The TPR is pleased to present a Case Study feature on Commercial Tool & Die, Inc., in Comstock, MI – winner, for two years running, of MoldMaking Technology Magazine’s Leadtime Leader Award for large shops.  This company is a winner for very good reasons, several of which will be revealed within this Q&A.  CTD’s Vice President, Todd Finley, provides some insight and we hope you enjoy this feature. 

 What is your company niche, and what does your company do that is notable, unique or different?

Commercial Tool & Die designs and builds medium to large plastic injection molds for the Automotive, Furniture, and Appliance industries.  We have a large and capable CNC Machining department that does contract machining for the Aerospace Industry as well as many other shops in the industry.  We have built a fine reputation for precise, efficient, and competitive CNC machining that helps us build injection molds that are superior in quality.  We design all of our molds in Unigraphics and utilize a paperless manufacturing system that is both efficient and less prone to mistakes and revision control problems. 
 

 When and how did you get into the industry, what

 attracted you to it?

Like many others, a family member got me a summer job in a mold shop in 1985.  I never left.  I found that building things is addictive and fun.  I also enjoy the fast pace and deadline pressure that you can only get in a job shop.

Relate a notable "best time" for your company.

I look back on the 1990’s as the best time, not only for our shop, but for most shops in the industry.  Work was abundant, payment terms were reasonable, and it was relatively easy to grow and be profitable.  We didn’t know how good we had it, when we had it so good.

Similarly, relate notable challenges that your company has overcome.

The last eight or so years have been extremely challenging as foreign competition has forced us to cut prices by 30% to 40%, while material prices have increased.  We have also had to figure out how to adjust to unfavorable payment terms and make tough decisions on work we would accept, at times turning down work when we really needed it.  We have slashed our costs and removed waste from our manufacturing process to remain profitable and competitive.  It has been tempting to cut corners on our product to match the declining prices, but we made a corporate decision to not only maintain our high quality, but to actually continue to improve the quality and value of the product we produce.  We don’t believe it is possible to sustain the business if we are producing an inferior tool.

An example of how we can add value for our customers is reflected in the following example:  We were contracted to build a second mold for a customer, producing an Energy Absorber for a Front Bumper to run in a 3,000 ton press.  We did not build the first tool and the tool we were contracted for was to help meet increased production volumes.  In the mold design phase, we suggested improvements to the overall product design and mold design concept that were ultimately approved.  We added significant cooling and reduced the complexity of the mold with a net result of a 50% reduction in cycle time and a mold that was more reliable in production.  Needless to say, our customer was very satisfied with the results and used our ‘capacity’ tool as the primary production tool as soon as it was ready.

 When you are working on projects with your customers, what aspects would you like
them to better recognize?

The importance of having good information early in the design stage.  It is extremely disruptive to our manufacturing process (that we have streamlined to remain competitive) if we have to back up or stop to accommodate late information.

List newly acquired technology, machinery or key personnel (in last year).
 

We recently purchased a Makino A81 horizontal twin pallet CNC machine for component machining.  We already have a Makino A99 dedicated to lifter and slide machining and we have experienced a great efficiency improvement by utilizing standard fixturing, automatic quick clamping, and utilizing the pallet system to streamline set-ups.  This new purchase will allow us to expand on this improved manufacturing system.  We have also hired a full time manager to focus on the Aerospace Industry, which we hope to grow.

 Has your company recently expanded?  Plans to expand or form partnerships/alliances?

We have not expanded recently, but we are always looking for good business opportunities and will add resources as needed.

We are in the process of forming a Tool and Die Collaborative with five other Michigan shops and applying for a Renaissance Zone.  There are definite advantages to working closely with other shops that have different specialties.  We hope to pool our resources to gain in areas like workload balancing, purchasing of materials, health care, and best practices. 
 

Are you involved in any industry organizations or educational programs related to the trade?

I am on the national Board of Directors for the AMBA.

CTD works with several local colleges, universities, and trade schools.

CTD has the only Dept. of Labor certified in-house apprenticeship program for mold-making and CNC machining in the Midwest.  This program has been so successful that we are starting a training company called Expert Technical Training to help provide on-line and custom training for our industry.  We are really excited about the opportunity to help educate the next generation of skilled tradespersons.

What do you think about changes occurring in the industry due to globalization?  How has it affected the way you do business?

We have been forced to become much more efficient and competitive in cost and quality.  The one advantage we have over foreign competitors is that we can service our customers for the life of the tool and be in their plant to help them solve issues.  We can also stand behind our product to ensure their success.  We have placed particular emphasis on customer service and responsiveness and we want to ensure every customer has a positive experience when they purchase from us.

What will the industry look like in 3 to 5 years?

Well, my crystal ball isn’t working at the moment, but I think that as the economy improves our business environment will improve with it.  Off-shore competition is here to stay, but I think many of our customers have had their eyes opened to the risks, incremental costs, and challenges they face when going off-shore.  I think everyone had to try it, because it was the ‘in’ thing to do and the initial pricing is compelling.  The North American shops that survive will be highly efficient and globally competitive, and they will do quite well.               

Additional Background Information:               

• Number of years in business:  56

• Current number of employees:  125 

• Current square footage:  85,000 

• Additional locations:  CG Plastics and CG Automation & Fixture, both located adjacent
  to CTD

• Website:  www.commercialtoolgroup.com

• Types of tools built and/or run:  Plastic Injection molds from 90 ton to 3500 ton.  Specialize in two-shot and complex or class ‘A’ molds 

• Industries served:  Automotive, Aerospace, Furniture, Appliance 

For more information:

Commercial Tool & Die, Inc.
5351 Rusche Dr. NW
Comstock Park, MI 49321
Phone: 616-785-8100

Email: Todd.Finley@CommercialTool.com

Or

Ray Henkel, Engineering & Sales: Ray.Henkel@CommercialTool.com