Radiall at Work: Molding Team

At the heart of the Château-Renault workshop, Molding plays an essential role in the manufacture of a range of plastic parts. Behind each component, there is a team with a wide range of skills working with rigor and precision, from adjusting the presses to final inspection. Keep reading to learn more about the team and gain insight into the tasks, organization and projects.

How would you describe the Molding team in just one word? What are the main tasks?

If we had to sum up the molding team in one word, it would be “competence.” The workshop is home to a wide variety of jobs: fitters-adjusters, operators, quality controllers, mold makers and so on. They all have one thing in common: a high level of professionalism and self-reliance. Some jobs are highly technical, such as that of a fitter-adjuster, which requires extensive expertise to set up the presses and inject plastic into the molds.

To explain molding in simple terms, it is primarily the transformation of plastic material that comes in the form of pellets. This is heated and then injected into a mold, where it perfectly fills the mold cavity before being ejected as a part. This is when the operators step in: deburring, manual work on parts, visual inspection, etc. Every action helps to guarantee the impeccable quality expected by our customers.

The team’s main tasks are:

• Respond to customer requests quickly and efficiently, with a very high level of quality, especially for the aerospace industry.

• Optimize workflows and reduce non-value-added tasks: by limiting movements, improving workstations and reducing waste.

How is the department organized?

The Molding department operates through a robust and highly efficient organization. The workshop currently has 47 employees at the Château-Renault site:

• 38 Operators divided into varying skill levels

• 5 Fitters-Adjusters

• 4 Quality Controllers

In this environment, everyone knows exactly what they have to do: Fitters-adjusters are responsible for starting up the presses, operators carry out manual operations and controllers ensure that parts comply with specifications. With this well-structured organization, we can work at a fast pace without ever compromising on quality.

What I like about my job is being able to manage the silicone activity independently and take on responsibilities. I also enjoy inspecting parts and preparing deliveries, as well as passing on my expertise. What’s more, working alongside different disciplines (mold makers, support roles) makes every day truly rewarding. – Isabelle A.

Is there any achievement that the Molding team is particularly proud of?

Yes, and everyone agrees: the creation of a structured training module for new recruits. Until recently, training was based primarily on individual experience and the dedication of the training officers without a clearly defined framework. A comprehensive training program has been designed to guide new employees through their first few weeks.

This module comprises a detailed checklist of operations to be mastered within the first 15 days, specially adapted training materials, and a final test to ensure that all essential steps have been understood (100% pass rate required to validate the training). However, what the team is most proud of is how involved the operators themselves are: they are the ones who truly embody the training, pass on the intricacies of the job and help new recruits to settle in.

The results speak for themselves: new employees become self-sufficient much more quickly, and the team is more cohesive. It is a truly collaborative effort, and one that is both structured and rewarding.

The strength of the Molding team really stems from the compassion we have for one another. There is a strong sense of solidarity, genuine team spirit, and a desire to share our knowledge. This collective momentum makes all the difference day after day. – Catherine M.

What is the next challenge for the team?

The next major challenge is an ambitious one: to integrate a cryogenic deburring system into all thermoplastic presses. Today, deburring relies on a shot-peening process that, despite its effectiveness, requires a lot of manual handling and blowing, a time-consuming task that can lead to MSDs*.

Cryogenics would greatly simplify this process. The principle is straightforward: Dry ice is sprayed onto all sides of the part to remove burrs without requiring any human effort. The parts come out virtually finished, without having to be blown or handled for long periods of time, which represents a significant time saving and a noticeable reduction in labor intensity.

This is a huge project, requiring significant investment and support from a specialized service provider. However, it would have a major impact: improved industrial performance, less strenuous work for operators and a smoother production workflow.

At the same time, the team is preparing for the arrival of two new presses, designed to boost production capacity and update an aging pool of machinery. These improvements will mean we can respond more confidently to rising customer demand.

Fitter-adjuster is a very fast-paced job, where no two days are alike. Being constantly in contact with other departments, such as Quality Control or Mold Makers, makes the work even more rewarding. And I particularly enjoy the thought process required in each situation to find the right settings. - Nicolas J.

*Musculoskeletal Disorders