JINX OR NOT, GOTTA’ BRAG! Arlington Plant Shatters Safety Record
Congratulations to all employees at the Arlington Plant for achieving 870 days (and counting) without a lost-time accident! They have beaten the previous record, held by the Headquarters Plant, by 232 days! And that’s really saying something, since the Arlington Plant is primarily involved in large-part molding with high-tonnage presses that require platforms at the machines, as well as the use of other equipment where caution must be exercised.
How’d they do it? Education and recognition, according to Plant Manager Bud Pagliccia. “Starting 10 years ago, we dedicated many communication meetings to safety. We want people to feel safe. And if there is an accident, we want employees to fill out an accident report without hesitation. We have a doctor and nurse on site to provide care and put preventive action into place. That’s how you get better, by preventing potential issues down the road.
“Along with wanting our employees to be safe, we also need to demonstrate that we can run a profitable business,” adds Pagliccia. “So we’ve had frank discussions about the impact of lost-time accidents on our bottom line.”
Pagliccia also credits management for supporting safety. “Anytime I ask for funds to correct a potential safety issue, it’s done. No questions asked.” He referenced a 30-year-old paint mixer that was presenting an ergonomic issue as an example. “Replacing it was a $7,000 investment. The requisition was signed within the hour.”
In terms of recognition, Pagliccia has sprung for gifts, steak dinners and other celebratory fare in honor of the milestones – 100 days, a year, and now, two years and counting. He has also mounted an electronic marquee in the plant that serves as a constant reminder of the number of days without a lost-time accident.
“We’re now at the point where it’s taken on a life of its own,” says Pagliccia. “No one wants to be the one to break the record!”
And when it’s over? “We start anew. We continue to work safely. That’s the expectation and that’s what’s important.”
Class of ’13 Paves Way for Successors
Mack just ‘graduated’ another successful class of 14 college interns, who have now swapped employee badges for textbooks to resume their studies.
The class of 2013 included Brittanie Bradley, Rensselaer Polytechnic Institute, Troy, NY; Brett Bushee, Vermont Technical College, Randolph, VT; Britney Coley, St. Lawrence University, Canton, NY; Alexander Cooley, Clarkson University, Potsdam, NY; Hilary Fox, Elmira College, Elmira, NY; Brendan Gleason, Cornell University, Ithaca, NY; Alex Goyette, Clarkson University, Potsdam, NY; Dustin Harrington, Albany College of Pharmacy & Health Sciences, Albany, NY; Joseph Keefe, Elon University, Elon, NC; Shay Mattison, Castleton State College, Castleton, VT; Libby Nunnikhoven, Bentley University, Waltham, MA; Adam Podolec, Rochester Institute of Technology, Rochester, NY; Asa Rogers, University of Vermont, Burlington; and Kristen Somple, Harvard University, Cambridge, MA. Their majors ranged from engineering, biology and physics to architecture, nursing and pharmacology.
As in the past, each intern returned to school with a completed project in hand to add to resumes and discuss with potential employers. Examples include validating software systems, creating a visual tool for sales revenue vs. forecast comparisons, and supporting implementation of specific manufacturing tasks for a key customer. Students were trained to use software and other equipment necessary to complete their projects. Additionally, Mack hosted several ‘Lunch & Learns’ that included visits to other Mack facilities, skill-building sessions, and student presentations on completed projects.
“It’s a win-win program on many levels,” says Jeff Somple, president, Mack’s Northern Operations. “Students have the opportunity to participate in valid summer internships while living at home. They learn about technical and engineering opportunities right here in the Northeast. And we develop a pipeline of future talent.”
Highschoolers’ Turn
Now that the college program is firmly established, Mack is extending its reach into area high schools. During October, some 90 students will visit Mack for ‘Made in Vermont’ days, a manufacturing careers workshop designed to showcase modern manufacturing and some of the products made here. They will learn about Mack’s menu of services by touring the f’real frozen beverage blender line, where virtually all services are rendered.
VMEC (Vermont Manufacturing Extension Center) officials, Dan Shea and Ken Walker, will then take them through a hands-on product-building exercise so they can better understand some of the complexities involved in full-scale manufacturing.
The Human Resources department will tie it all together with a session on the skills needed in manufacturing, whether pursuing a college-oriented engineering track or a post-high school technical track, and relative career paths at Mack.
“We hope this initial effort will open the door to other projects with area schools,” says Somple. “We will have a sign-up board in case any students want to return for some one-on-one or small group sessions in specific departments. Hopefully, this will pave the way for prospective college interns and, possibly, future employees.”
Mack Acquires Synectic Engineering
Effective today, Mack Molding is the new owner of Synectic Engineering, Inc., a medical product development company in Milford, Ct. Synectic employs 18, including mechanical, electrical, biomedical, materials, chemical and quality engineers, clinicians, and industrial designers. Facilities include 3D CAD platforms, a model shop, an in-vitro tissue lab, and an on-site Class 10,000 clean room for pilot manufacturing. Both privately owned companies, the terms of the agreement are not being disclosed.
“This investment will allow Mack to augment its front-end services with clinically driven product development professionals that focus 100 percent of their time and talent on product design and development,” says Jeff Somple, president of Mack Molding’s Northern Operations.
“Today, OEMs want to hold fewer suppliers responsible for more,” Somple adds. “By augmenting Mack’s capabilities with engineering resources skilled in proof-of-concept, pre-clinical R&D, and product development from design to pilot manufacturing, everyone wins. Synectic gains the financial backing of a large contract manufacturer with extensive prototyping and manufacturing services. Mack adds more firepower and muscle behind its front-end services. And customers have the luxury of managing and auditing only one supplier with a robust complement of product development, molding, metal and total product manufacturing services.”
Synectic and its current employee group will remain in Milford under the supervision of its new president, Adam Lehman, who previously served as VP and chief operating officer. “We are all very excited about joining Mack, which will allow us to keep programs under one roof,” says Lehman. “We’ll now be able to provide uninterrupted oversight and support for the full life of a program, rather than handing off to a manufacturing partner. The whole process will now be seamless, because Mack will be involved from the start.”
Synectic operates on a fixed pricing model, rather than taking the more conventional time and materials approach. “Fixed fee forces a more time- and cost-conscious path,” says Lehman. “We have senior level staff, each with more than 10 years of medical product development experience, and an established process that facilitates success.” The product development process features five phases, including project definition, concept development, engineering development, design for manufacturability, and pilot manufacturing.
“There’s a gap between the genesis of a product design and its move into full production on the manufacturing floor,” says Somple, who believes these five phases will fill that gap. “It’s one thing to make one or two or 10 of something to validate a concept and function. It’s quite another to manufacture in large quantities at a competitive price in a productive fashion with good quality.
“All too often, manufacturers find themselves embroiled in concurrent engineering on design while under tremendous pressure to launch into full scale production at the same time,” he continues. “That’s really not the way to do it. This acquisition is going to strengthen our ability to bridge that gap, both for ourselves and our customers.”
It’s Spring! And You’re Invited…
With snow-melt and green grass, spring is finally beginning to surface in Vermont! And with it comes a busy trade show season for Mack.
Here’s the lineup:
- May 13-15 – Plastics in Medical Devices, Westin Waltham-Boston, Booth #17
- June 5-6 – OrthoTec, Orthopaedic Capital Center at Grace College, Warsaw, IN, Booth #403
- June 18-20 – MD&M East, Pennsylvania ConventionCenter, Philadelphia, Booth #2307
Key technical and engineering staff from MackMedical, our medical products group, will be at each show to meet with attendees, answer questions, and discuss current and future projects. Mack Prototype, our prototyping and low-volume manufacturing group, will also be represented at MD&M East.
Click on any of the logos to go directly to the registration page. And if you’re planning to attend any of these shows, please consider this your invitation to stop by. We’d love to see you!
Bonnie Simon: 30 Years of Medical Manufacturing
Editor’s Note: Another Mack is ME! post, this series spotlights the people and personalities behind our services. Check back frequently or subscribe to the feed, as these profiles will be interspersed with news updates on a regular basis. We hope you’ll enjoy getting to know us!
Name: Bonnie SimonTitle: Manufacturing Manager, Headquarters Plant
Her job? Bonnie is responsible for planning, scheduling, and supervising the work of nearly 100 production employees who form the nucleus of Mack’s contract manufacturing service. Her medical-device expertise in new product development and process introduction, quality, ergonomics and operations management plays a key role in serving and growing Mack’s roster of customers in the medical marketplace.
Time at Mack: 8½ years.
Favorite Mack memory: Bonnie enjoys all of the employee appreciation dinners and other celebrations that Mack hosts for its employees. “It is important to recognize the hard work that Mack employees put into their jobs.”
Favorite part about working at Mack: Bonnie loves the security she feels at Mack. “Mack has such a diverse customer base here that there has never been a need to go international.” Having been responsible for transitioning US-based operations to Thailand, Ireland and Mexico for former employers involved in mergers and acquisitions, she has never feared that Mack would do anything similar. “I have never once regretted coming to Mack. Over the years, Mack has diversified into many different services and markets. There are so many new products and people coming through our doors — there is nothing but excitement every single day.”
Experience: Bonnie graduated from Adirondack Community College (Queensbury, N.Y.) with an associate’s degree in business administration. After, she attended SUNY Empire State College (Saratoga Springs, N.Y.), where she studied business administration and economics. Bonnie joined Mack with over 20 years of medical manufacturing experience, including stints with Hudson RCI; Tyco, Inc. (Argyle, N.Y.), where she was production manager in the Tracheal Tube Operations for six years; and Mallinckrodt Medical, Inc., the world’s leading endotracheal tube manufacturer that was later acquired by Tyco.
Personal life: Bonnie grew up in the Cambridge, N.Y., area. She moved to Greenwich, where she currently lives with her husband, Jerry, who owns and operates a used car dealership in nearby Cambridge. They have been married for almost 34 years, and are the parents of three adult sons – Kyle, Eric and Isaac – who all live locally. They have one grandson and two granddaughters.When not at work: Bonnie enjoys gardening, decorating and her family. “Every other second, I’m with my grandchildren. I’ve been blessed to be a part of their lives and really watch them grow. Being that close with your family is a very special thing.” She also spends every summer at her lake house on Lake Cossayuna, where she swims and boats daily. Her winter getaway is to a recently purchased home in Florida.
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