The TPR interviewed Carlo Nudi, General Manager of Star Plastics, a custom injection molder located in Mississauga, Ontario, Canada. The company recently moved into a new, 100,000-square-foot facility and purchased new machinery to accommodate the company’s significant growth and we asked Carlo to tell us the strategy behind the success.

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

We currently supply a wide product mix in the automotive, industrial, and consumer markets. Our machine capacity ranges from 40 tons to 1500 tons with complete project management capabilities from tool design to mass production. We also manage secondary operations such as paint and chrome plating applications with on-line and off-line assemblies. We continue to invest in the latest technology of machinery and automation equipment with a focus on continual improvement activity providing cost competitive solutions.

When and how did you get into the industry, what attracted you to it?

I started working in a small custom molding shop part-time while in school full-time. I grew a strong interest in the industry and decided to join the company full-time after graduating with a business education in 1995. I continued my education part-time with industry related courses. Most of my strengths are in establishing and implementing management systems, Engineering and Quality management. I joined Star Plastics in June 2005, sharing a common vision with Jas Dhami (Founder of Star Plastics) and Tony Suriano (Operations Manager).

Jas Dhami obtained 20 years of experience in molding prior to starting his own business. He started with two small molding machines and grew the business with dedication and committed employees.

Tony Suriano joined Star Plastics in 2003 as the Operations Manager. He has more than 22 years of molding experience with extensive technical knowledge.

Some of the recent challenges we have overcome is the successful launches of immediate transfers with little to no lead-time. One of our strengths is the ability to launch projects into mass production quickly and efficiently. We are committed to work aggressively towards each project until a stable and capable process is established maintaining profitability.

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

We have established a reputation based on honesty, integrity, and reliability. Our management team is committed to project success and to provide cost competitive solutions through continual improvement activities. Our new business model includes the adoption of 5S practices and lean manufacturing techniques.

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

There has been a lot of exciting activity in the last 2 years. We have purchased 11 Mitsubishi injection molding machines (hydraulic) in the last year ranging from 180 tons to 1500 tons. The year before, we acquired 8 machines, taking us to a total of 37 machines today. The significant growth has allowed us to expand and strengthen our management team with dedicated people among all departments.

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

In the last 2 years we have expanded from 34,000 sq ft to 73,000 sq ft of manufacturing and warehouse space, 40 to 170 employees, 18 to 37 injection molding machines. Our 3 – 5 year business plan includes a second facility with heavy tonnage equipment which would range from 1,000 tons to 3,000 tons.

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

We are in the process of exploring the development of a program at a local college where we will bring in students as part of the course criteria. The students will obtain training and field experience and Star Plastics will have the opportunity to hire young talent upon graduation and develop them into process technicians.

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

It is definitely a challenge to remain competitive in this industry – especially in the lower tonnage work. It has become a requirement for many of the big players to source a certain percentage of work to low cost regions such as China and India, but the lead times and freight expenses are among the only leverage we have to remain competitive. This has influenced our vision to grow towards heavier tonnage molding with value added assemblies.

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

I see the industry becoming more and more competitive as the world gets smaller with globalization. Our long term strategy is to remain diversified in several markets and to become very strong and competitive in the niches we select.

Additional Background Information:

Number of years in business: Star Plastics was established in 1989.

Current number of employees: 170

Current square footage: 73,000 square feet

Additional locations: None at this time.