Plastic Injection Molding Consulting Specialist
Associate Consultant Ken Coppins
Injection Molding Consultant
Plastic Injection Molding Consultant Ken Coppins
Ken Coppins is a plastics industry veteran with extensive molding experience in the North American Automotive industry.  Located in Ontario, Canada, he has expertise with many varied plastic resins and Injection Moulding machines.  Ken has developed and implemented operational strategy and standards for numerous manufacturing plants, leading staff and incorporating manufacturing methodologies such as Cell Manufacturing, In-line assembly, labour optimization and Scientific Moulding to improve productivity / profit.  His background includes resin conveying/loading systems, chilled water and IMM auxiliary equipment.
  • 5 years in 3D mold design consulting
  • Trained injection molding specialists
  • Process analysis and troubleshooting using scientific molding techniques 
  • Many years in capital equipment technical training, sales, and marketing
  • Knowledgeable about most upstream, downstream and specialty injection molding processes – material preparation and conveying, mold preparation, water cooling, automation, sprue separation, welding/joining, printing, IML, insert molding, multi-material techniques, gas injection, structural foam, etc.
Professional Experience
Private Practice
August 2016 - Present
Toronto, Ontario, Canada
  • Sole Proprietor providing Injection Moulding Consulting Services in Ontario
  • Cycle time reduction / Productivity Improvements and Technical Training using Scientific Moulding Principles
  • Data Driven Focus
 
July 2004 – July 2016
Polybrite Magna, Injection Moulding Specialist
Richmond Hill, Ontario, Canada
  • APQP Team Member – Mould Design Input / Mould Trial to Production Responsible
  • EOA Tooling review and Design – Verify Moulding Process and EOA Tooling in Production setting
  • Day to Day Operation / Trouble-shooting and Continuous Improvement
  • Issued Maintenance and Tooling WOs as required
  • Performed DOEs as Required
  • Implemented Process Master Documentation to ensure repeatability
  • Training and Development for all Injection Moulding Technical Staff
  • Mould PM Responsible – Using outside source until in house Tool Room was established
  • New Technology Review and Recommendations
  • Capital Expenditure Review and Recommendations
  • Daily / Monthly Reports / KOIs
 
January 2002 – July 2004
Polycon Magna, Senior Process Engineer
Guelph, Ontario, Canada
  • APQP Team Member – Mould Design Input / Mould Trial to Production Responsible
  • EOA Tooling review and Design – Verify Moulding Process and EOA Tooling in Production setting
  • Day to Day Operation / Trouble-shooting and Continuous Improvement
  • Issued Maintenance and Tooling WOs as required
  • Performed DOEs as Required
  • New Technology Review and Recommendations
  • Daily / Monthly Reports / KOIs
 
December 1999 – December 2001
PMP Plastics, Plant Manager
Mississauga, Ontario, Canada
  • Responsible for all functions relating to the start-up of a new 100,000 sq. ft. manufacturing plant with annual sales in excess of $35 million and a workforce of up to 75 employees utilizing 15 Injection Moulding Machines
  • Managed production requirements,  staff development, scheduling, maintenance, and operational procedures while controlling manufacturing costs, product quality and inventory levels
 
January 1996  – December 1999
Polybrite Magna, Moulding Manager
Richmond Hill, Ontario, Canada
  • Managed Technical staff as well as 20 employees in injection moulding  / paint line facility - improvements relating to plant efficiencies, cost control and molded quality
 
December 1991 – December 1995
Manchester Plastics, Moulding Superintendent
Scarborough, Ontario, Canada
  • Managed all operational issues, process development and improvements for Injection Moulding facility.
  • Responsibilities included 75 plant staff, 25 Injection Moulding Machines, assembly lines, supporting equipment and utilities
 
Certifications
  • CPR Certified
  • 6 Sigma Green Belt
 
Technical Skills
  • Scientific Molding Principles – John Bozzelli
  • Plastic Part Design – Glen Beall
  • Basic Machining
  • Basic Hydraulics
  • CNC Programming
Ken has worked with the following Resins:
ABS                                                      PC
Acetal                                                  PC ABS
Acrylic                                                  PP
ASA                                                      Polysulfone 
Polyphenylene Oxide (Noryl)        PVC (flexible)
HD PE                                                  PVC (rigid)
LD PE                                                   TPO
Nylon (many types)                         Styrene

Ken is familiar with the following Injection Moulding Machines:
Engel                   Kawaguchi-Niigata
Husky                  Toshiba
Battenfeld          Arburg
Nissei                   Van Dorn
Klockner              Natco
Krauss Maffei     CH America

And also familiar with:
Insert Molding                                     Hot Stamping
Molding for Painted Parts                 Pad Printing 
Molding for Plating