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History
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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
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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
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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
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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
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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
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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
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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
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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)
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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
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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
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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
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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
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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)
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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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