Canadian Plastics 2013 INJECTION MOLDING SURVEY RESULTS *survey results based on 24 responses...

Canadian Plastics2013 INJECTION MOLDING

SURVEY RESULTS

*survey results based on 24 responses

Sponsored by:

Survey Methodology

The Injection Molding Benchmark Survey was sent in late November 2013 to 489 people at injection molding shops on the circulation list of Canadian Plastics magazine, with one survey going to one respondent per facility. It was emailed up to three times if we had the recipient’s email address and received 24 responses.

To encourage response, we offered to put respondents’ names in a draw for a $200 cash prize.

2013 INJECTION MOLDING SURVEY RESULTSSponsored by:

1. Which best describes the molding operations at your plant?

Exclusively captive molding

Exclusively proprietary

Exclusively custom molding

Captive molding with some custom molding

Custom molding with some proprietary molding

0% 10% 20% 30% 40% 50% 60% 70% 80% 90% 100%

9%

9%

35%

13%

35%


2. What markets do you serve? (Check all that apply)

Automotive

Construction

Consumer goods

Packaging

Electronic

Medical

Other

0% 10% 20% 30% 40% 50% 60% 70% 80% 90% 100%

61%

17%

44%

26%

26%

22%

17%


3. Which of the following service capabilities does your plant provide its customers? (Check all that apply)

EDI or e-procurement

Design (CAD)

JIT production

Printing/decorating

Welding/bonding

Mold manufacturing (in-house)

Assembly

0% 10% 20% 30% 40% 50% 60% 70% 80% 90% 100%

52%

74%

74%

57%

61%

57%

96%


4. What percentage of your plant’s 2013 budgeted expenses was allocated to employee training?

4+%

3%

2%

1%

0%

0% 10% 20% 30% 40% 50% 60% 70% 80% 90% 100%

4%

13%

26%

57%

0%


5. What percentage of your plant’s 2013 budgeted expenses went to product research and development, either on-site or off?

4+%

3%

2%

1%

0%

0% 10% 20% 30% 40% 50% 60% 70% 80% 90% 100%

26%

13%

35%

22%

4%


6. In which of the following areas do you have formally implemented policies and programs? (Check all that apply)

Safety

Training

Cost reduction

Recycling/waste management/environmental

Modified work for worker comp. cases

Preventative/predictive maintenance

0% 10% 20% 30% 40% 50% 60% 70% 80% 90% 100%

87%

74%

74%

61%

52%

83%


7. Is your plant certified to an ISO or QS9000 standard?

Yes

No

In process

0% 10% 20% 30% 40% 50% 60% 70% 80% 90% 100%

78%

17%

4%


8. What kinds of polymers does your facility currently process? (Check all that apply)

Commodity resins

Engineering resins

Specialty resins

Bio-based/biodegradable resins

0% 10% 20% 30% 40% 50% 60% 70% 80% 90% 100%

78%

70%

30%

13%


9. What do you estimate will be the total amount of resin consumed at your plant in 2012 in lbs?

Average

0 2,000,000 4,000,000 6,000,000 8,000,000 10,000,000 12,000,000 14,000,000

13,105,000


10. What percentage of the injection molding machines at your plant fall into the following tonnage ranges?

99 tons or less

100-249 tons

250-499 tons

500-749 tons

750-1499 tons

1500+ tons

0% 10% 20% 30% 40% 50% 60% 70% 80% 90% 100%

72%

72%

78%

44%

28%

22%


11. What was your average machine utilization rate for the past year?

91-100%

80-90%

70-79%

60-69%

50-59%

40-49%

Less than 39%

0% 10% 20% 30% 40% 50% 60% 70% 80% 90% 100%

17%

22%

28%

11%

11%

11%

0%


12. What was your plant’s average part reject rate for the past year?

Over 5%

4.1-5%

3.1-4%

2.1-3%

1.1-2%

0-1%

0% 10% 20% 30% 40% 50% 60% 70% 80% 90% 100%

6%

0%

33%

11%

22%

28%


13. Of the projects you quote on, what percentage turn into business?

50+%

21-50%

11-20%

0-10%

0% 10% 20% 30% 40% 50% 60% 70% 80% 90% 100%

17%

28%

11%

44%


14. Compared to 2012, how was your business volume in 2013?

Up more than 10%

Up 6 to 10%

Up 1-5%

The same

Down 1-5%

Down 6-10%

Down more than 10%

0% 10% 20% 30% 40% 50% 60% 70% 80% 90% 100%

29%

18%

18%

24%

0%

6%

6%


15. Compared to 2013, what do you anticipate your business volume will be in 2014?

Up more than 10%

Up 6 to 10%

Up 1-5%

The same

Down 1-5%

Down 6-10%

Down more than 10%

0% 10% 20% 30% 40% 50% 60% 70% 80% 90% 100%

22%

11%

22%

28%

11%

0%

6%


16. What percentage of your product is shipped outside of Canada?

Over 75%

51-75%

26-50%

0-25%

0% 10% 20% 30% 40% 50% 60% 70% 80% 90% 100%

12%

12%

41%

35%


17. What is the number of injection molding machines at your plant?

16+

11-15

6-10

1-5

0% 10% 20% 30% 40% 50% 60% 70% 80% 90% 100%

29%

35%

24%

12%


18. What percentage of your machinery is more than five years old?

Over 75%

51-75%

31-50%

0-30%

0% 10% 20% 30% 40% 50% 60% 70% 80% 90% 100%

65%

18%

12%

6%


19. a) Were any new injection molding machines purchased for your plant in 2012?

Yes

No

0% 10% 20% 30% 40% 50% 60% 70% 80% 90% 100%

53%

47%


19 b) If yes, were the purchased machines…

New

Pre-owned

Both

0% 10% 20% 30% 40% 50% 60% 70% 80% 90% 100%

78.0%

22.0%

0.0%


20. Will new injection molding machines be purchased for your plant in 2014?

Yes

No

Don’t know

0% 10% 20% 30% 40% 50% 60% 70% 80% 90% 100%

41%

18%

41%


21. a) Do you intend to buy…

New machines

Pre-owned

Both

0% 10% 20% 30% 40% 50% 60% 70% 80% 90% 100%

54%

8%

39%


21. b) Is it for replacement of old equipment or for additional capacity?

Replacement

Additional capacity

0% 10% 20% 30% 40% 50% 60% 70% 80% 90% 100%

31%

69%


22. Was any auxiliary equipment purchased for your plant in 2013?

Yes

No

0% 10% 20% 30% 40% 50% 60% 70% 80% 90% 100%

88%

12%


23. Will new auxiliary equipment be purchased for your plant in 2014?

Yes

No

Don't Know

0% 10% 20% 30% 40% 50% 60% 70% 80% 90% 100%

59%

6%

35%


24. a) Were any new linear (3-axis) robots purchased for your plant in 2013?

Yes

No

0% 10% 20% 30% 40% 50% 60% 70% 80% 90% 100%

41%

59%


24. b) Will any new linear robots be purchased for your plant in 2014?

Yes

No

Don't Know

0% 10% 20% 30% 40% 50% 60% 70% 80% 90% 100%

29%

35%

35%


25. a) Were any new articulated (6-axis) robots purchased for your plant in 2013?

Yes

No

0% 10% 20% 30% 40% 50% 60% 70% 80% 90% 100%

19%

81%


25. b) Will any new articulated (6-axis) robots be purchased for your plant in 2014?

Yes

No

Don't Know

0% 10% 20% 30% 40% 50% 60% 70% 80% 90% 100%

6%

53%

41%


26. How many employees work at your plant?

250

100-249

50-99

20-49

10-19

1-9

0% 10% 20% 30% 40% 50% 60% 70% 80% 90% 100%

18%

12%

24%

18%

18%

12%


27. What is the hourly rate paid to a machine operator, excluding benefits?

AVERAGE

0 2 4 6 8 10 12 14 16 18 20

$13.50


28. Please select the province/territory where your plant is located:

Yukon

Saskatchewan

Quebec

PEI

Ontario

Nunavut

NWT

Nova Scotia

Newfoundland

New Brunswick

Manitoba

British Columbia

Alberta

0% 10% 20% 30% 40% 50% 60% 70% 80% 90% 100%

0%

6%

12%

0%

83%

0%

0%

0%

0%

0%

0%

0%

0%

Canadian Plastics 2013 INJECTION MOLDING SURVEY RESULTS *survey results based on 24 responses...

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