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Mack Sees Uptick in Medical Consumables Manufacturing

February 23, 2015 by Mack News Leave a Comment

FOR IMMEDIATE RELEASE

.

ARLINGTON, Vt. (February 23, 2015) – MackMedical/Mack Molding is investing $2 million to expand its cleanroom molding and assembly capacity to handle significant growth in the medical consumables market, it was announced today by Jeff Somple, president. Recently named president of all of Mack Molding, Somple emphasized that “while we’ve been involved in orthopedic disposables for some time, this marks our first foray into high‐volume, single‐use components for a Class III medical device. It’s a critical step that will open up a whole new market sector for us,” he explains.

To accommodate the work, Mack is building its third ISO Class 8 molding and assembly cleanroom at its headquarters plant here, which will house four electric presses from The Japan Steel Works (JSW). It is scheduled to be certified by April 1, 2015, at which time Mack will begin validation runs. “We’ll be shipping parts by the end of April,” adds Plant Manager Rich Hornby.

Beyond the main molding and assembly area, the cleanroom will include space for part conveyance from an adjacent soft‐walled cleanroom that will house a robotically automated 500‐ton press. Servo‐controlled radio frequency and ultrasonic welding systems will be installed, as well as automated particulate, temperature and humidity monitoring.

Mack is adding four electric presses, including two 44‐ton vertical machines and 60‐ and 199‐ton horizontal presses. From JSW’s ‘advanced’ series, they feature a 62 micro second servo control circuit that delivers high‐speed performance with increased precision and reliable quality.

Semi‐automated equipment will be installed to support molding and assembly, which includes overmolding of extruded tubing. The presses will be vacuum‐fed by a modular bank of dryers located just outside the cleanroom.

In addition to this investment, Mack has two other ISO Class 8 cleanrooms ‐‐ a molding cleanroom with six electric presses and an assembly cleanroom that is used for non‐sterile packaging of medical disposables, light sonic weld assembly, and temperature‐ and humidity-controlled functional testing. There is also a 24‐hour whiteroom operation that houses four hydraulic presses dedicated to small part medical molding.

Deepens Engineering Talent
In addition to adding cleanroom capacity and technology, Mack has also augmented its pool of medical device engineering expertise and realigned staffing to better serve the needs of its customers.

David ClatworthyDavid Clatworthy and Timothy Hutchings bring more than 50 years of combined engineering and manufacturing experience to Mack. Clatworthy came to Mack from AngioDynamics, Inc. (Glens Falls, N.Y.), where he worked in both manufacturing and quality engineering for catheter products and molded components for 14 years. His final position there was principal manufacturing engineer, molding. Earlier, he managed manufacturing and quality engineering departments for Medefab, Inc. (Jaffrey, N.H.) and Vermont Medical Inc./AngioLaz, Inc. (Rockingham, Vt.).

A Six Sigma Black Belt, Clatworthy holds a bachelor’s in industrial engineering technology from The State University of New York Institute of Technology (Utica), and an associate’s in mechanical technology from Onondaga Community College (Syracuse, N.Y.). At Mack, he will have manufacturing engineering responsibilities for both single use and reusable orthopedic product lines.

Timothy HutchingsTimothy Hutchings joined Mack after a 12‐year stint as senior project engineer for Covidien/Tyco Healthcare (Argyle, N.Y.). Most recently, he served as system expert for dialysis manufacturing equipment and helped lead multiple validation activities. Earlier, Hutchings worked as an R&D engineer on large ultra‐violet light disinfection systems for ITT/Wedeco (Poultney, Vt.), and as a nuclear plant electrician for GPU Nuclear/Amergen/Exelon Nuclear (Forked River, N.J.).

Hutchings has earned a Six Sigma Green Belt and holds a bachelor’s in electronics engineering technology from Grantham University (Kansas City, Mo.) and an associate’s in nuclear technologies from the University of Phoenix (Phoenix, Ariz.). He will have manufacturing engineering responsibilities for medical device consumables.

Both engineers report to Scott Hodges, who has recently been promoted to manufacturing engineering manager. Hodges has worked at Mack for nearly 20 years in both quality and manufacturing engineering. Most recently, he was responsible for all engineering, operations, production planning and compliance for the manufacture of several FDA Class III medical devices. A graduate of The State University of New York (Buffalo), Hodges earned a bachelor’s in aerospace engineering, and an associate’s in math and science/engineering from Hudson Valley Community College (Troy, N.Y.).

Forms Customer‐focused Production Teams
Scott HodgesHodges’ promotion is part of a recent manufacturing reorganization designed to separate engineering from production at the headquarters plant. “Previously, the line was blurred, so engineers were taking on production and scheduling responsibilities, and were  too involved in day‐to‐day operations,” explains Hornby. “Instead, we want to focus engineering resources on cost reductions, continuing improvement efforts, and new program launches.” To facilitate that, customer‐focused production teams have been created. Each team includes a planner, supervisor, manufacturing engineer, quality engineer and buyer, all with clearly defined roles and responsibilities. “We’ve added headcount, yet we’ve been able to keep labor, as a percentage of sales, very low,” says Hornby. “We’re starting to see the efficiencies of this type of system, and so are our customers.”

About Mack Molding
Mack Molding is a leading custom plastics molder and supplier of contract manufacturing services. Mack specializes in plastics design, prototyping, molding, sheet metal fabrication, full-service machining and medical device manufacturing. Founded in 1920, Mack is a privately owned business that operates 11 facilities throughout the world. Jeff Somple is president and Don Kendall is CEO.

Filed Under: Press Releases

Plastics Molding: The Path of Least Resistance

December 10, 2014 by Mack News Leave a Comment

December 2014, Medical Design Briefs
Plastics Molding: The Path of Least Resistance
By Michael Hansen, PhD, Senior Technical Development Engineer, MackMedical/Mack Molding

Filed Under: Bylined Articles

Nancy Cefalo Promoted to Top HR Role at Mack

November 10, 2014 by Mack News Leave a Comment

FOR IMMEDIATE RELEASE

ARLINGTON, Vt. (November 10, 2014) – Nancy Cefalo, a 14-year employee of Mack Molding, has been promoted to human resources director for the company’s three Vermont manufacturing facilities, it was announced today by President Jeff Somple.

Nancy Cefalo, Director, Human Resources“Nancy has served as human resources manager during her entire tenure at Mack and is uniquely qualified for her new role and responsibilities,” says Somple. “Beyond HR experience, she brings a well-rounded background of nursing, organizational management and mediation training to the table. She will be a welcome addition to my staff.”

Cefalo replaces Kevin Dailey, who has served as HR director for 16 years, but has now accepted the new position of VP, human resources, for Southwestern Vermont Health Care (Bennington, Vt.). “Kevin has been on the Board of Trustees of the hospital for several years and has a strong interest in healthcare issues,” adds Somple. “This is a wonderful opportunity for him — we wish him the best in his new and exciting position.”

Before joining Mack, Cefalo worked as a home health nurse for Manchester Health Services, Manchester, Vt., where she established the Maternal Child Health Program for wellness and preventive care. Earlier, she was owner/operator of a family restaurant, where she managed all operations, including human resources.

Cefalo holds an associate’s in nursing from Bunkerhill Community College (Charlestown, Mass.), a certificate in mediation/conflict management from Woodbury College (Montpelier, Vt.), and a bachelor’s in organizational management/psychology from Ashford University (Clinton, Iowa).

Active in the community, she is a member of the board of directors for the Battenkill Valley Health Center in Arlington and past treasurer of the Arlington Area Child Care board of directors. Cefalo is also a member of the Society for Human Resource Management.

Cefalo lives in Arlington, Vt., with her husband, Richard. They are the parents of three adult children and are now enjoying two young grandsons. When she isn’t working, Cefalo enjoys cooking, hiking and bicycling.

About Mack Molding
Mack Molding is a leading custom plastics molder and supplier of contract manufacturing services. Mack specializes in plastics design, prototyping, molding, sheet metal fabrication, full-service machining and medical device manufacturing. Founded in 1920, Mack is a privately owned business that operates 11 facilities throughout the world. Don Kendall is CEO and chairman.

Filed Under: Press Releases

Fixed-Fee vs. Time-and-Materials: Which Outsourcing Pricing Structure is Right for You?

September 15, 2014 by Mack News Leave a Comment

September 2014, MD&DI
Fixed-Fee vs. Time-and-Materials: Which Outsourcing Pricing Structure is Right for You?
By Jeffrey Ransden, Engineering Manager, Synectic, a Mack Molding company that specializes in full-service product development.

Filed Under: Bylined Articles

Jeff Somple Named President of Mack Molding

September 2, 2014 by Mack News Leave a Comment

Jeff Somple, President, Mack Molding Co.FOR IMMEDIATE RELEASE

ARLINGTON, Vt. (September 2, 2014) – Effective today, Jeff Somple, president, Mack Molding Northern Division, will assume the presidency of all of Mack Molding, it was announced by Don Kendall, CEO and chairman of the privately held Mack Group.

“Jeff took over the helm of our northern division in 2002 and has delivered sustainable, profitable growth ever since,” says Kendall.  “That has been particularly challenging in the face of the Great Recession, financial market chaos, massive job loss throughout the country, and a tepid economic recovery. For Mack, this time period also reflected a significant loss of sales from the computer and business equipment sector to overseas low-cost labor; diversification of our markets with a major thrust toward medical device manufacturing; grass-roots development of a full-service machining center; and the acquisition of an engineering services company to enhance upfront design capabilities. Jeff has demonstrated strong, confident leadership throughout each of these challenges. I am extremely pleased he has chosen to accept this one as well.”

As president of Mack Molding, Somple will be responsible for both its northern and southern divisions, including five manufacturing facilities in Vermont, North Carolina and South Carolina; Mack Prototype, a prototyping and low-volume manufacturing facility in Massachusetts; and Synectic, an engineering services group in Connecticut. Kendall will remain as CEO and chairman of Mack Group, which includes Mack Molding and Mack Technologies.

Somple has been with Mack since 1988, when he joined the sales department. He moved quickly up the ranks to vice president, sales/engineering, and then president, Northern Division. Earlier, Somple was northeast regional sales manager for five years for Continental Extrusion Corporation, an extruder, printer and converter of plastic packaging in Garden City, N.Y. He also owned and operated his own restaurant in Black Rock, Ct.

Somple holds a bachelor’s degree from Middlebury College, Middlebury, Vt. He and his wife, China, are the parents of three daughters and make their home in Manchester Center, Vt.

Filed Under: Press Releases

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