Annual Plant Safety Meeting

At Dimatic, safety is a top priority, and this can be seen throughout our company.  While we work hard on a daily basis to maintain a safe environment for all employees and visitors, we believe that safety is an area that we must continually improve upon .  Dimatic has several programs in place to ensure we are appropriately preventing accidents while also ensuring our employees can all respond in case an emergency would arise.  These programs range from Hazardous Communications and SDS (Safety Data Sheet) Procedures to Emergency Evacuation Procedures, Forklift Safety, and Lockout-Tag out Procedures.  Our safety committee meets on a recurring basis to review these procedures, respond to employee requests, and help ensure all employees can work in a safe environment.   

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Last week, we held a company-wide gathering for our annual plant safety meeting.  At this event, Dimatic leadership reviewed the different procedures we have in place, discussed best practices, answered questions, and took recommendations for improving our safety programs.  Following this gathering, all employees were quizzed over the policies and the employees receiving the highest scores were awarded with gift cards. 

Dimatic employees have shown their dedication to a safe working environment by working 687 straight days without a lost time accident.  We are well on the way to topping our previous record of 2093 days.  By continually reviewing our safety policies and ensuring all employees are properly educated, Dimatic is dedicated to providing all employees with a safe environment.

Tracking Production: Bear Tracker

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Operating 3 shifts and maintaining a working plant 24 hours a day comes with a wide range of challenges.  Not only must staff be maintained to manage machinery and protect quality, but tracking the production becomes a challenge when working with 20 different injection molding machines.  For years, Dimatic has used a proprietary custom-made system to help track its production, reduce down-time, perform regular maintenance and quickly address issues that arise.

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This system, titled “Bear Tracker”, uses sensors placed on each machine to track cycle time, downtime, startups, and shut downs.  Using the projected cycle time limits and real-time tracking, Dimatic can quickly and easily see what how machines and operators are doing, as well as receive live cost analysis on their jobs. 

In addition, this Bear Tracker system saves historical data so that Dimatic can maintain a record of efficiency and best evaluate how changes effect the process.  Dimatic regularly uses this data to improve their own processes, improve efficiency, and eliminate scrap.

Recently, Dimatic improved their system further by linking this Bear Tracker system with their warehouse inventory software to help automate their inventory tracking system. With this improvement, parts are flawlessly tracked from machine to warehouse to shipment, with a digital footprint throughout the process.

Dimatic’s Bear Tracker system gives them a distinct edge against competing injection molders as it allows us to track our machines in real-time, quickly respond to issues that arise, improve efficiency, keep customers aware of production status, and automate our production.

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Global Impact

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Being a family-owned small/medium sized business operating out of Omaha, Nebraska, it is hard to imagine that Dimatic can have a global reach, however, our employees have worked hard to make excellent quality product and spread our name, so that our products can not only be found throughout the Midwest, but throughout the world.

Dimatic has become an international company, with products that can be found across the globe.  Parts produced in our molding department can be found on irrigation center-pivot systems as far away as Dubai.  Panel covers made at Dimatic can be found throughout Mexico.  Edible dog bones made at Dimatic can be found being enjoyed by dogs in India.  Molded control boxes are used throughout Europe.  Likewise, our custom line of pulleys can be found across the globe.

Through years of excellent products, increased international trade, and remaining open to new opportunities, Dimatic has truly become an international company.

Recycling/Regrind

In a world where environmental impact has become a house-hold topic, manufacturing companies must take it upon themselves to help reduce their waste and the impact on our planet.  By utilizing regrind within the injection molding process, Dimatic has been eliminating scrap for decades.

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Within the injection molding process, there is a potential for a significant amount of waste.  The two most common types of waste are through scrapped parts and molded runners.  Parts can be scrapped for many reasons, however, out of tolerance or warped parts are the most common cause.  Cold runner molds will have scrap in the form of runners, which are the left-over plastic “tunnels” by which the melted plastic is fed into the mold cavity.  Parts typically need to be trimmed from the runners.

Dimatic has been recycling this “scrapped” material by grinding down the scrap parts and runners.  Once these have been ground down to a pellet size, they are mixed in with virgin material in the proper ratios to continue making new parts.  By recycling the material in this manner, Dimatic is able to have virtually zero waste product in our process.

By understanding our responsibility to maintain resources, Dimatic has been running our injection molding operation virtually waste-free for years by recycling and regrinding our runners and scrapped parts.

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Warehouse Advantages

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At Dimatic, we pride ourselves in providing various services to our customers in order to help them be successful.  One such way we have done this is through the use of our warehouse.  By utilizing our 20,000 square foot warehouse, we are able to provide several advantages to our customers that can help them save money, hit deadlines, and quickly respond to the fluctuating needs of everyday business.

By manufacturing products in one lot and storing them in our warehouse, we are able to save customers money during production by reducing set-up cost, and providing parts as they are needed.  In addition, customers can rest easy knowing their products will be safely stored in our warehouse, which is equipped with a security system and loaded sprinklers. 

We offer blanket orders, kan-ban, and forecast commitments, all to fit the needs of those we work with.  We are able to provide special drop-shipments from our warehouse as well as professional packaging. 

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If you have any questions about how warehousing your parts can be beneficial to your company or would like to see our facility, please contact us.  We would love to hear from you!

Use our warehouse and you can say goodbye to lead times on last-minutes jobs and say hello to cost savings and just-in-time delivery.  Whether you have 10 parts, or 1,000,000, our warehouse helps provide you with a solution to save money, hit deadlines, and respond to the demands of modern business.

Multi-Process Jobs

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At Dimatic, we work on a vast array of project, many of which utilize more than one of our manufacturing capabilities.  Once such project was a timing belt pulley we recently built for a client.  This small, high precision part required work within our molding, tooling, and assembly departments. 

After designing and building the mold in-house, the first process in creating this part is a process called over-molding.  In this injection molding process, a single part is created from two or more materials.  The first material, in this case the aluminum hub, is partially covered during the injection molding process with the injected plastic.  For this pulley, an aluminum hub is placed into the mold before a cycle is ran.  After the cycle, in which a glass-filled polycarbonate fills the remaining cavity within the mold, a single part falls out which is the combination of the plastic and aluminum.

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Following molding, the part is taken into our assembly area where it is drilled and tapped in order to add set-screws to the part.

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Finally, the part goes through a process called “Sonic Welding”.  This is a process, commonly used for welding together plastics, which uses high-frequency mechanical motion to generate heat to join together two thermoplastics.   This process forms a molecular bond between parts.  In regards to the pulley, sonic welding is done to weld the flange onto the body of the pulley and finish the part.

By having the capabilities to complete all of these steps in-house, we were able to save our client money and time while providing them with high quality parts to fit their needs. Dimatic’s versatility and diverse abilities met the challenge of this project and provided a high-quality part to its client.

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Bracket In-Die Tapping

Dimatic was presented with a challenge by a Fortune 500 company to produce large monthly quantities of a .040” thick galvanized steel bracket that also requires two threaded holes.  The part design appears to suggest a stamping/forming operation, followed by tapping operations for the #6-32 threaded holes.  The print is shown here:

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Dimatic designed and built a progressive die to pierce the five holes, cut the outside contour and additionally tap the two holes.  All of this is done in a single stroke of the punch press, and includes two in-die tapping heads to complete the threaded holes. 

This efficient use of design, tooling and labor saves costs, improves production efficiency and provides consistent quality through the entire process.  Dimatic’s design, tooling and production team has scored again! 

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Molded Plastic Spiral

Dimatic was requested to help design and produce plastic parts of a very unique shape by a customer.  The part involves a spiral design with holes through the part which is used in a mixing operation.  It was to be molded from a food grade plastic in several colors.  After considering the customer’s requirements and product application, a final part was designed using Dimatic’s Pro-Engineer* solid modeling software to maximize the efficiency of the part’s mixing capability as well as to produce a part that is consistently injection moldable.    The part desgin is shown here:

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Dimatic combined the use of 3-D printed samples, along with viewing 3-D models to work with the customer to design the finished part.  Dimatic then designed and built a two cavity mold for the job.  The HDPE part’s intricate shape requires mechanical cams to core out the center section and complete match-offs on the contoured walls.   Using the 3-d design database and extensive use of CNC (Computer numerically controlled) Milling, EDM (Electrical discharge machining) and Wire EDM technologies, Dimatic’s designers and toolmakers made the product happen.  The mold was built with top quality materials and standards and some of the electrodes and components are shown here:

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Our molding production department produces the parts in many colors and completes the product through a packaging operation which includes a shrink wrapped clear tube.  See sample parts below:

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Through excellent communication with the customer on the part’s requirements and the expert use of high-tech design tools, Dimatic met the challenge of this project and brought quality through the entire process including end user packaging.  Dimatic’s design, tooling and production team has scored again!