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Providing precision custom molded elastomeric components to the world.

Company Information


History

This year, Quality Synthetic Rubber, Inc. will celebrate 42 years as a corporation. Dennis Kaiser and Don Skuza, formed the company in 1966 in a small building in Oakwood Village, Ohio, with the two owners serving as the company's sole employees.

In 2007, Blue Point Capital Partners, in conjunction with QSR's existing management team, recapitalized QSR with a focus of pursuing growth opportunities in North America and Europe, as well as implementing its Asian growth strategies.

QSR now employs over 300 dedicated and quality minded employees using state-of-the-art equipment to produce precision custom molded elastomeric components for the automotive, industrial and medical markets.


Quality Policy

Quality Synthetic Rubber is committed to providing "World Class" Precision Molded Elastomeric Components. This commitment is a company wide dedication to continuous improvement and customer satisfaction.


Facility

In the spring of 1986, Quality Synthetic Rubber moved their operations into a new 40,000 square foot facility located in Twinsburg, Ohio. This new plant, which took a year to design, is clean, well lit, fully air conditioned, and features a layout that maximizes process and material flow.

In 1989, an additional 42,000 square feet of manufacturing and warehouse space was built.

In 1995, 31,000 square feet was added to accommodate our in-house mixing operation, giving QSR's facility a total of 113,000 square feet.


Engineering

To satisfy your objectives, Quality Synthetic Rubber is available to provide expert assistance in material selection and part design.

Prototype and production tools are designed in-house enabling QSR to provide parts that meet or exceed the rigid quality standards necessary for today’s automotive and industrial applications.

Our part design capabilities are enhanced by the use of three-dimensional CAD systems. Our current workstations run Dassault Systemes S.A. Solidworks as well as I-Deas NX Series. This software contains the most current 3D modeling technology as well as robust drafting capabilities. In addition, Autodesk's AutoCAD and Solidworks are used for mold and press design.

QSR stays on the cutting edge of product design with the use of advanced finite element analyses or FEAs. We utilize HKS's high end ABAQUS software suite to perform sophisticated computer simulations of parts and assemblies in their application. The results that are extracted from these analyses allow QSR to optimize a product design in a timely and efficient manner before any parts are created or any physical testing is performed.


Reliability Lab

To aid Engineering in new product and material development, the Reliability Lab utilizes the necessary equipment to perform Thermal Cycling, Submergible Air Leak, Dielectric, Force Testing and other customer specified testing on finished product. This reliability testing capability provides essential data, which ensures that the product design exceeds the customer’s requirements.


Material Laboratory

Quality Synthetic Rubber's certified Material Laboratory is an integral part of our engineering and development process. The three basic functions of the laboratory are material development, quality testing of materials, and prototype tool evaluations.

Material development consists of the formulating and tool testing of materials to meet the needs of customer applications. High temperature, low temperature, compression set, fuel and oil resistance are a few of the tests that are performed on these materials.

Quality testing is performed on materials used in the production of finished part and on the finished parts themselves. This testing is done to ensure that material and parts are produced at the highest level of quality.

Prototype tools, and material development are often evaluated simultaneously. Typically, new materials are processed in prototype molds to determine the best combination of properties, process parameters and tooling design for a particular part. Material shrinkage is also carefully calculated from the prototype mold to ensure that dimensionally accurate production tooling and parts are produced.

The materials laboratory is currently GP10 certified with General Motors and holds a A2LA Laboratory Accreditation with the American Association for Laboratory Accreditation.


Rubber Mixing and Milling

Quality Synthetic Rubber has four mill rooms housing four mills and a calender. One of these mills is a high tech machine equipped with a 150 H.P. variable speed drive which enables QSR to regulate the speed of the rolls for efficient sheeting of any elastomer. The power roll adjustment allows for quick and precise control of material thickness and the adjustment provides variable volume control for mixing and sheeting a large range of batch sizes and weights. The power guides, which flip up for easy cleaning, are made from a special nylon material that eliminates the metallic oxide contamination caused by conventional bronze guides.

A new 75 liter internal mixer, complete with a weigh-up line, and a batch-off system was installed at QSR in the first quarter of 1996. Along with various silicone and fluorocarbon materials, a number of other types of rubber will be processed through our new mixing facility.


Molding

Quality Synthetic Rubber's seven molding rooms contain over 110 presses, all which have been designed by QSR's engineering to produce precision parts in high volumes. The latest design employs a vacuum molding chamber which eliminates the most common trapped air and nonfill problems associated with molding in normal atmospheric conditions. All presses are "overbuilt" relative to their particular tonnage to minimize deflection. The presses are microprocessor controlled so that all critical parameters, including time, temperatures and pressures are held within narrow limits and all values are continuously monitored and displayed on the large computer control screen to facilitate our S.P.C. Program.


Liquid Injection Molding (L.I.M)

For high volume production of silicone parts, QSR engineering has developed patented liquid silicone molding and tooling technology to produce parts fully automaticly with no runner waste or part flash.


Two and Three Component Molding

QSR engineering has recently developed patented technology that enables fully automatic molding of two and three component part assemblies.

This technology enables QSR to produce assemblies consisting of rubber and plastic components, that typically require separate molding operations and subsequent assembly operations, to be completely manufactured in a single automated system. This enables QSR to produce such assemblies more efficiently and at a lower overall cost.


Finishing

Depending on the part configuration, application or specification, products may require some type of finishing operation after being molded and prior to being shipped to our customers. This finishing may involve post curing, air cleaning, washing, drying, talcing, oiling, deflashing, and/or a combination of these processes. Each part number is controlled by a computerized bar-coded master router system to ensure all applicable finishing operations are completed.

Quality Synthetic Rubber utilizes the latest technology available in cryogenic deflashing equipment, some of which, have been modified by QSR engineers to achieve precise control of deflashing media and barrel temperatures. These key process parameters must be controlled to economically finish quality parts time after time.


Receiving and Shipping

Received materials are entered into the computer network system which verifies received goods versus ordered goods and initiates our lot traceability system. Adequate floor space has been designated for the receipt and storage of raw materials until all applicable testing has been completed.

QSR has a state-of-the-art shipping department which features the following systems:

an inventory data base, multilevel box traceability, electronic digital counting scales, and computer generated bar-coded labels. These bar-coded labels include a part picture along with date and serial number identification that enables QSR to trace these parts back through every operation including receipt of the raw materials.


Quality

Quality Synthetic Rubber is currently ISO/TS 16949:2002 certified, our registrar is ABS Quality Evaluations. We provide engineering assistance to our customers, and within the next year plan on achieving Design Responsibility certification.

Quality Synthetic Rubber is committed to continuously improve the quality of our finished products. These improvements are accomplished through the use of Design of Experiments, SPC, Worker Involvement Teams, Quality Meetings, and ASQC functions. Gantt Charts are used to monitor and document the progress of all continuous improvement activities.

Four programmable camera based measuring systems enable us to collect quick and accurate measurement data from our molded parts is used for both in process and initial sample dimensional requirements. These systems eliminate human error and greatly increases measurement speed and accuracy. These systems have enabled QSR to become certified with Delco Electronics on their Dimensional Measurement Accreditation Program.

The implementation of our ongoing plantwide Quality Training Program and utilization of the best equipment has enabled QSR to continuously improve the quality and cost competitiveness of its molded products.


M.I.S. (Management Information Systems)

The M.I.S. Department is the information nerve center for Quality Synthetic Rubber's daily production activities. In order to maintain smooth operations and provide up-to-the-minute information, the M.I.S. computer system is constantly monitored with data being logged as it is generated.

QSR's computer operations have grown to become the foundation of our entire Continuous Improvement Program. One example of this is our bar-coded Work In Process/Inventory System which allows us to operate more efficiently along with minimizing the chance for human error.

Our electronic communication system allows us to communicate and better serve our customers in the form of ASN's (Advanced Shipping Notices), Material Releases and web based shipment tracking.

The M.I.S. staff provides customized programming, 24 hour support, in-house training, auditing, and daily backups. Hardware and software are continually updated as required to meet Quality Synthetic Rubber's growing needs, both internally and for our customers.


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