Going PRO

Ferris State University Provides Injection Molding Operator Training for Rexair LLC

By Stephen Wolfer

From February through June, 35 team members at Rexair LLC in Cadillac, Michigan, received injection molding operator training led by Ferris State University through a Going PRO Talent Fund award from the state of Michigan.

“Rexair has been a recipient of the Michigan Going Pro grant for five years,” said Kari Wineland, Rexair manager for human resources. “The grant has allowed Rexair to create an internal succession pipeline for skilled trades and to support training for other new technology.” 

Benefits of the training are multifaceted, said Matt Schroeder, Rexair’s plant manager. “Our employees are our greatest asset. Continuing to invest in their knowledge and skill sets benefits the organization as a whole. Maintaining well-trained employees results in a safer work environment, improved efficiency, and a more skilled workforce.”

Stephen Wolfer, a Professor of 32 years in the Plastics Department, was sent to deliver the training as part of Ferris State University’s Corporate and Professional Development, which acts as a liaison with professional industries.

“FSU was selected as the training source due to Rexair having a great working relationship with key members at FSU,” Wineland said. “These members have provided excellent in-person training focused on our injection molding equipment and processes.”

Founded in 1936, Rexair manufactures home cleaning systems and is based in Troy, Michigan, with a manufacturing facility in Cadillac, where the training took place.

Before the training started, Wolfer met with managers, supervisors, and shift employees to assess their needs. “In addition to the development of the technical training, this informal assessment allowed the course to be customized to best suit their needs,” he said.

Rexair wanted the training delivered at the beginning of each attendee’s shift. “Rexair scheduled training so attendees did not have to arrive early or stay past their normal work hours. In addition to being convenient, this allowed employees to stay attentive and retain the content of the course,” Wolfer said.

Injection molding is a manufacturing process that produces parts by injecting molten plastic material into a mold. It can be performed with a variety of materials. Because of high heat, pressure and many moving parts, safety in the manufacturing process is paramount.

The objective of the training was to inform Rexair’s trainees of the safety concerns and develop a better understanding of the technology that they are working with.  To obtain these objectives, the topics presented were: Injection Molding Safety, Injection Molding Molds, Injection Molding Machines, Injection Molding Cycles, Injection Molding Thermoplastic Materials, and Injection Molding Part Defects.

In addition, Rexair recently purchased and implemented state-of-the-art, all-electric injection molding machines, so the training touched on the benefits of these new machine capabilities, including artificial intelligence functions. Each group of workers completed training over six days.

Each session, Wolfer delivered a two-hour session that contained theoretical training room PowerPoint presentations as well as production floor activities. “It was an important component of the training to follow up the technical presentations with activities on Rexair’s production floor to help the attendees apply the training immediately in their work environment,” he said.

Michigan’s Going Pro Talent Fund requires pre and post-testing of all content presented. All attendees engaged in the training and shop floor activities and, as a result, all participants accomplished significant improvements in their post-training scores. After the post-training assessment, the employees received a certificate of completion from Ferris State University’s Corporate Development Department.

“The post-training scores achieved by Rexair’s team members were impressive, and they should all be proud of their scores,” Wolfer said. Plant manager Schroeder added: “The operator training was a great success. We quantify training success by measuring gains in safety, knowledge, ability, and employee morale. All the training we have contracted through Ferris State University has proven successful in these categories.”

In addition to Injection Molding Operator Training at Rexair, Wolfer teaches Injection Molding and Automation courses at Ferris State University and has delivered robotics, injection molding and mold setting at other plastics businesses across the United States, Canada and Mexico.