Welcome to APM

APM Core Competencies

Value Added Services

• Product Design & Development Assistance

• Program Management

• Supply Chain Sourcing & Management

Manufacturing

• Injection Molding

• Assembly

• On-site & Off-Shore Tooling

APM

• Founded in 1971• On-site mold building & repair added in 1980• Employee owned and operated• Combined annual sales of $20,000,000 for 2013• Approximately 120, non-union employees• Certified to ISO 9001:2008, ISO 14001 Pending• U.L. listed for molding and assembly

Facility Facts and Figures

• Location provides easy Interstate access • 50,000 sq. feet of manufacturing space• 60,000 sq. feet of warehousing space• 7,500 sq. foot machining, tooling & prototyping facility• 5 Acres of additional property for future expansion • Satellite warehouse facilities

Supply Chain Sourcing and Management

Comprehensive Domestic and Off Shore Supply Chain Network for:

• Aluminum & Zinc Die Casting

• Steel Stampings

• Screw Machine

• Aluminum & Plastic Extrusion

• Roll Forming

• Thermal/ Vacuum Forming

• Spring and Wire Forming

• Electrical Components

• Various forms of prototype & production tooling

• Powder coating, E Coating, Wet Paint, Polishing, Plating

Engineering Capabilities

• Product development assistance

• Industrial Design assistance

• Application analysis

• Material selection

• Design enhancement and “value” engineering

• SolidWorks CAD

2. Daily Status Review Meeting

7. Employee suggestion program

4. A3 Project Management

3. Accountability Board

6. Leader Standard

Work

1. VisualMetrics

5. Gemba Walks

8. Process Tracking

9. Problem Solving

Lean Management Systems based on Shingo principles of operational excellence

APM’s “LEAN” Implementation

3. Problem Statement (What is unacceptable with the current situation?)

Double - stacking issues, too much inventory at ABC and SC, not electronically triggered per pitch, trailers are stacked up 1 Footprint reduced by 50%

in the lot, assembly line has been shorted various parts, not a designated time or door for ABC 2

3 Throughput is decreased to minutes4 Inventory reductions met5 Increase ABC deliveries from 9 to 11

4. Scope (What is included and/or not included in the project)

Delivery (to KWE and to Think supermarket), receiving, warehousing, auditing, invoicing, and scheduling

5. Objectives (Objectives should coincide with problems. Include quantitative goals. Ie.%)

Deliver materials to a designated door at a designated time to a designated supermarketReduce inventory by 50%No disruptions to the line due to part shortagesImprove the ekanban process by introducing multiple scans at Steelcase and ABC

8. Current Condition (What is the current situation? Display your thinking in this box)

Numerous part shortages (trailers double stacked, batch scanning, lack of communication for spikes, double and triple handling of parts after delivery)

Dates 9/19 9/26 10/3 10/10 10/17 10/24

1 Assemble Team 3 Conduct total landed cost analysis4 Define mat'l handling requirments5 Determine floor space req.6 Develop kit list communication7 Determine trucking req. (Sunday night?)8 Define ABC internal ordering process9 Determine exit strategy

10 Define Roles/Req./Std. Work (dock flow)11 Determine trucking route / times12 Establish min and max inventory levels

Project Complete - signoff & gradingShaded Area Key: Green indicates task complete

Red indicates task late

Measures should coincide with Objectives and be measurable. Measures should correspond to your tracking measures

6. Measures 9. Current Results1 Inventory2 Throughput (replenishment signal to delivery)3 Floorspace (dock to supermarket)4 ABC part shortage interruptions

2. Team: Leader: John T 7. Team: Art H, Rick P, Mary M, Mark C, Jim V, Brian J, Adam A 12. Approvals: 0

7 hours10,100 sq ft??

4 hoursxx minutes5,200 sq ft

Target Results

1. A3 Project Plan: ABC Delivery Process

11. Implementation Plan (List of major steps required to complete the project)

10. Future Condition (What would we like things to look like in the future?)

8 hours

No disruptions from Steelcase / ABC part shortages

S e p t 1 8 , 2 0 0 8

T h in k R e c e i v i n g ( F u t u r e )

R o y a l T e c h n o l o g i e s

R o ya l D e live r y T r u ck

D e d ica te d S te e lca se d r ive r

K it

B u ild P a ckF IF O F IF O

S h i p p i n g

M a te r i a l s M g m t

S ca n A S N

S A P

E va lu a te d R e ce ip t

S e tt le m e n t

D e d ic a t e d R o y a l D o o r - 1 0 1 3

R e c e i v i n g

S ca n e ka n b a n

ca r d s

E ka n b a n s ig n a l fo r r e p le n ish m e n t

R e tu r n e m p tie s

ABC

Sept 18, 2008

Think Receiving (Current)

ABC

SAP

SupplySync

I

9 deliveriesEvery 2 hours

Delivery to WH and

supermarket

Scan ASN- printing eKanban

cards

Unload truck

Delivery to line side

2 personsPT: 15 minCT: 60 min

180 backs150 arms240 seats

1 person15 mins

1 peson60 mins

2 persons9 – 20

minutes

I

1day

I

1day

900 sec 900 sec 3600 sec 1200 sec

12.35 hours

6600 seconds

Arms: 480Seats: 540Backs: 200

FabricCenter

3 times / hour2 pitches each

WS1: backs, arms, seats

WS2:Lineside,Cards, totes,

mange super -rmarket

.75 hours 3.6 hours 0

8.25 hours

5S Status ReviewMeetings

A3 Project Planning Value Stream MappingKaizen events

Visual Metrics

Accountability Boards

Injection Molding

Injection Molding

• 38 molding machines

• Press Sizes: 5 to 725 tons

• Flexibility ranging from high volume fully automated work cells to low volume, short runs, and prototyping

Injection Molding

• Injection molding of thermoplastics

• Closed loop control Cincinnati Milacron molding machines available for close tolerance molding

• Runner removal robots and 3 axis full servo parts removal robotics for reduced part cost and repeatability

Scheduling & Real Time Monitoring

Integrated Scheduling for MRP and EDI

Automotive Interior, Exterior & Drivetrain

Automotive Seating, Latch Assemblies, Relays, Hybrid system components, etc.

Motor Housings & Fans

IT and Communications

Gears

Secondary Operations

Part Removal Robots

Secondary Operations

• Press-side assembly and testing

• Drilling, tapping, ultrasonic assembly and

Heat Induction welding

• Pad printing and hot stamping

• Painting, plating and vacuum metalizing available

Secondary Operations

• Vibration Welding • Ultrasonic Welding & Insertion

Assembly

Assembly

• 15,000 sq. ft of Assembly Cell floor space with room for expansion

• Assembly ranging from basic “kitting” of parts to complex assemblies with mechanical and electrical testing

• U.L. Listed Manufacturer

Complex Mechanical Assemblies

Remote Power Taps

Medical CPU Housing, LCD Monitor Mount, and Keyboard

Platform

LED Task Light Assembly

Quality Assurance

Quality Assurance & Inspection

• ISO 9001:2008 Registered (14001 pending)• ASQC/ASQE Trained Auditors• Level 1 thru 4 PPAP experience• Fully equipped QA laboratory• Optical Comparator, Wenzel Programmable CMM• Omnimark Moisture Analyzer• Color Spectrophotometer, MacBeth Lighting Booth &

Gloss Meters for precision color matching

Advanced Production Quality Planning

Optical Comparator & CMM’s

Programmable Wenzell CMM

Optical Comparator

Color Spectrophotometer for objective color measurement

Color Matching

Mac Beth Color Booth

Injection Molds & Tooling

On site tool shop for Prototyping, Assembly Fixturing, Production

Tooling and Repairs

Southern Mold & Tool

• Wholly owned subsidiary of APM (located on the same property) dedicated 100% to APM’s customer base

• Class A production molds, low volume “bridge” & prototype tooling

• Production machining of components to support assembly.

• 24 hr availability for emergency repairs

Southern Mold and Tool

Haas CNC Machining Centers

EDM Machines

Charmilles Roboform 30 Agie Elox Mondo 3

Off Shore Tooling Options

Warehousing & Shipping

• 60,000 sq. foot heated warehouse

• Flexible stocking programs

• 6 Loading Bays available for Trailer drop off

• 24 hour staffing of warehouse

• Drop shipments and Distribution Program availability

• Satellite warehouse for additional storage and distribution

Summing it all up...

QUALITYSERVICESUPPORTDELIVERYVALUE

APM…

American Plastic Molding Corp.P.O. Box 480

965 South Elm StreetScottsburg, IN 47170

812-752-7000 PH812-752-5155 FAXsales@apmc.comwww.apmc.com