Looking for contract overmoulding?  Or mould flow analysis?  Or injection moulding design feedback?  You have found the place.

Associate Consultant
Paul McGinty

Paul McGinty - Injection Moulding Specialist

Paul McGinty has extensive experience in plastics and tooling, from his early beginnings as a moulding machine operator to Journeyman Tool Maker and eventual factory ownership. In 1993, Paul established Advantage Plastics Corp. a small plastics and tooling company where he served as President/CEO for 15 years until its sale in 2008.  He has a total of 35+ years in the industry. His manufacturing experience includes, Tool and Die building, plastics processing, transfer/insert molding, 2 shot multicolor/material molding, FDM and DLMS 3-D Additive Manufacturing, Thixomolding (mag/alum injection molding), compression silicone moulding, vacuum/thermo-forming, M.I.M. moulding and tooling, In-Mould Decorating (IMD/IML), many Secondary operations including die cutting/trimming, sonic welding, pad printing, adhesives and assembly.

PROFESSIONAL EXPERIENCE

March 2015 - Present
Irwin Enterprises Inc - Project Manager

Responsibilities:

• Initiate, develop and maintain customer and supplier relationships
• Assist customers in Design for Manufacturing, product development and material selection
• Quote plastic part production and new tooling costs
• Produce 3-D part models using FDM printing technology
• Develop tooling and molding strategies to meet customers production needs and financial goals
• Design and build plastic injection molds, secondary operation/assembly fixtures and other tooling
• Program 4 axis CNC milling machines and EDM machines
• Manage tooling department, personnel, and projects
• Support Molding Department thru complex problem solving, process improvement, procedures, and training
• Oversee and perform new/revised tooling and materials sampling
• Diagnose, repair, and maintain molding and tooling equipment
• Develop and implement sound scientific molding practices
• Develop and implement quality control systems, PPK, SPC
• Perform F.A.I.R and PPAP inspections and documentation
• Software - Microsoft Office Suite, Solidworks, MasterCAM, Cimatron

June 2014 – Feb 2015
Parkway Products LLC - Sr. Manufacturing Engineer

Achievements:

• Over seen the production plant design, implementation, and logistics for the relocation of the plastics molding facility, facilitating the separation of the plastics molding from the magnesium molding operations.
• Studied Thixomolding (magnesium injection molding), worked to improve process and machine failure issues. Discovered rudimentary processing and primary machine component (Barrel, Feed Screw, screw tip and nozzle) failure issues. Implemented new replacement parts supplier and developed SOP for molding processes. Resulting in reduced machine down time and increasing product yield and quality.
• Introduced superior tooling suppliers and implemented design improvements to existing tooling improvements to improve yield in both magnesium molding and die trimming operations. 
• Started the implementation of CCD and 2D laser for part Presence/Absence detection and part/fixture inspection on molding machines, die cutters and CNC machining centers.

Responsibilities:

• Collaborate with Molding, machining and finishing engineering teams, perform failure root cause analysis, develop solutions and implementation plans.
• Implement growth plans of machinery and tooling within budget and on time.
• Report directly to Plant General Manager and VP of Operations (corp.).

Feb 2008 - May 2014
OtterBox LLC. - Manufacturing/Process/Tooling Engineer 

Achievements:

• Extensive travel in South East Asia, Singapore, Mexico and trough out the USA to work with our supply chain base vendors and suppliers to provide training, Engineering, Quality, Manufacturing and technical support to help build a better product and a build a stronger business partnership.
• Instrumental in the Product Launches of all Apple, Samsung and HTC product lines.
• Worked with material suppliers to develop proprietary thermo plastic materials. New material resulted in a 52% savings in material costs and reduced customer returns from 22% to 7% due to the improved material properties and performance.
• Thru dedicated teamwork developed Modular Mold Base system, Tooling Standards and Product Quality Testing Standards and Procedures. Improved tooling lead time from an excess of 90 days to 28 days.

Responsibilities:

• Follow all employee guidelines and Quality Systems Regulations as defined by Otterbox practices, policies and Standard Operating Procedures to ensure that customer requirements and regulations are met.
• Review part designs for mold ability and manufacturability and provide feedback to Otterbox design engineering team
• Perform Mold Flow analysis to support Design For Manufacturing on product design and tooling changes
• Manage timelines for the design, fabrication, and qualification of injection molds, assembly fixtures, testing fixtures, and any tooling or equipment requirements
• Manage tooling vendor timelines and provide daily and weekly progress reports to Otterbox project management team
• Facilitate vendor requirement reviews and mold specifications and acts as vendor liaison for all molding/tooling related issues
• Facilitate the inspection of molds, fixtures, gages, and dispositions discrepancies in collaboration with Otterbox design personnel and project needs.
• Facilitate technical design reviews of injection molds, assembly equipment, measurement requirements, and test fixtures and gages.
• Facilitate qualification of injection molded components per Otterbox SOP documents including mold Installation 
  • Qualification, process characterization studies on molded parts (DOE), Operational Qualification, Performance
  • Qualification and perform final FAIR-P and FAIR-A for production approval.
• Evaluate and if necessary, update procedures and methods to successfully design, fabricate and validate injection molds, assembly fixtures and other tooling through vendors or within the Otterbox development system
• Provide sustaining engineering on molds and fixtures / gages already in production
• Maintain and operate a small OtterBox tool room for the purposes of fixturing, prototypes.
• Software - Microsoft Word, Excel, PowerPoint, Autodesk Simulation, Moldflow Adviser. Moldflow Synergy, SolidWorks, SolidCAM, TecSoft ProCAD/CAM, ProEngineer.

Aug. 1993 - Feb. 2008
Advantage Plastics Corp - President-Owner/CEO
Fort Collins, CO

Achievements:

• Provided customers with product development and design services for plastics and tooling.
• Designed, manufactured and marketed proprietary product line.
• Grew company from a single machine, one-man operation to a 15 machine, 14 employee operation including a 2-man Toolroom
• 15 years of profitable operations. Annual Sales up to 2.5M

Responsibilities:

• Overseen all daily operations
• Accounts Receivable/Accounts Payable, Sales and purchasing
• Customer relations/service
• Design and manufacture product and tooling to meet customer requirements.

March 1987 - Feb 1994 
RCS Precision Tooling - Journeyman Toolmaker/GM
Boulder, Colorado

Achievements:

• Implemented plastic injection molding capabilities.
• Key influence to implementing CNC capabilities to a previously manual tool shop.
• Wrote all manual CNC code, implemented and mastered Tecsoft ProCAD/ProCAM software.
• Served as General Manager from 1992-94.

Responsibilities:

• Management of 7 toolmakers
• Mold design.
• CNC programming, operation and training.
• Customer relations
• Tool building, plastics setup/processing and molded product quality control.

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