Bright Plastics Manager Using Synergy SPC Product.
Bright Plastics Manager Using Synergy SPC Product.

Bright Plastics manufactures plastic injection-molded parts for a diversity of industries, resulting in broad expertise and experience in meeting a range of industry-specific manufacturing needs. While they are able to manufacture to the requirements of almost any industry, their equipment, facilities, and quality certifications are especially aligned for markets such as Medical Device Manufacturing and Pharmaceuticals, Consumer Products and Diagnostics, Automotive, Government/Military, Heavy Truck, Waste Management, and Nuclear Materials Packaging.

They have been in business for 25 years, manufacturing approximately 5,000 products. “Because we are known in the industry as one of the best injection molding manufacturers, continuous process improvement is a core value for Bright Plastics,” remarked Kate Bryant, Director of Quality for Bright Plastics. “Our method for implementing this core value is using the data-driven Six Sigma process.”

“Bright Plastics uses Synergy SPC data to not only to track where we began, but also to track each improvement along the way,” remarked Bryant. “Today, customers are becoming increasingly more savvy and specific about the information they want about the products we produce for them. When I joined Bright Plastics, one of my top priorities was to make the laboratory first class. I knew I needed a system that could provide me the flexibility to meet these ever-changing customer demands“ commented Bryant.

“Bright Plastics has experienced an integral reduction in its scrap rate by 40% in the last two years and is now able to meet increasing customer requests immediately. This reduction is due in part to the use of the Zontec Synergy 1000™. I couldn’t be more pleased with the performance of the Synergy product,” remarked Bryant.

“Because our primary method of gaining new business is referral from customers and other business associates, Synergy really enables us to differentiate ourselves from the competition,“ said Bryant. “Providing additional information instantly reinforces to the customer, the added value we provide.” “For example, when we are having a customer audit, we take the auditors to a station running Synergy. That way, we can easily pull up any information they request immediately.”

“Automatic email notifications have really made my life easier. Now, I don’t have to wait for someone to tell me when something is out-of-control,” said Bryant. “In fact, when we have auditors come in I deliberately take them to a station running Synergy, put in an out-of-specification condition, an automatic email goes out to my email that I show the auditor. They are very impressed.”

This flexibility is not only limited to the auditing process but also is important when a customer wants additional information about a shipment as well. “Often times customers decide they would like additional information provided with their shipment. Using Synergy, I can immediately make the changes, and include it. They are very impressed, in fact our customers rave about the Synergy product.”

Bryant has found that using Synergy has helped her to demonstrate value through the flexibility of information she can provide to her customers as well.

“I enjoy the fact that if a customer requests additional information on their Certificate of Analysis, for example, I can immediately add that information on the next production run. Also, if a customer emails or calls me asking for some additional information, with the Synergy reporting system, I can generate the additional information they need, select the appropriate chart or report and immediately email it to them for approval. One customer said, ’Wow! You can do it, that fast?’”

”We have found the Synergy product to be a competitive advantage for us. We are able to leverage the detailed information from Synergy to continue to differentiate ourselves in the marketplace,” said Bryant.

Zontec is proud to have played such a complimentary role in Bright Plastics’ drive for continuous process improvement.

Executive Summary

Customer

Bright Plastics manufactures plastic injection-molded parts for a diversity of industries, resulting in broad expertise and experience in meeting a range of industry-specific manufacturing needs. While they are able to manufacture to the requirements of almost any industry, their equipment, facilities, and quality certifications are designed for numerous markets. For more information on Bright Plastics, visit their website at:
http://www.brightplastics.com/

Challenges

Customers increasingly require more specific data about products
Maintain leadership in the marketplace

Solution

• Zontec’s Synergy 1000™

Results

• Able to meet increasing customer requests immediately
• Integral reduction in scrap rate by 40%, in last 2 years
• Software to track and monitor continuous process improvements
• Demonstrate rapid responsiveness to customers requests

Quote

“I enjoy the fact that if a customer requests additional information on their Certificate of Analysis, for example, I can immediately add that information on the next production run. Also, if a customer emails or calls me asking for some additional information, with the Synergy reporting system, I can generate the additional information they need, select the appropriate chart or report and immediately email it to them for approval. One customer said, ’Wow! You can do it, that fast?’”

— Kate Bryant, Director of Quality for Bright Plastics

For a PDF of the Bright Plastics success story, please click on Bright Plastics