Ge-Shen Adds Liquid Silicon Rubber injection moulding process

With growing demand for liquid silicon rubber, especially in the medical, infant and baby care, electronics and industrial industry, Polyplas, a subsidiary of Ge-Shen has invested in Liquid Silicon Rubber (LSR) injection moulding capability and is ready to supply LSR products to its customers.

Why Liquid Silicon Rubber?

LSR injection molding provides consistent part quality and consistency as compared to other other elastomers and thermoplastics. It is able to achieve high precision, and if done well, is burr or flash free, direct from the mould.

Silicon rubber is tasteless and odorless, can be sterilized in a variety of methods and can be formulated to comply with FDA requirements. It is naturally resistant to bacteria growth, making it a perfect choice for medical devices and products.

It is durable, and can withstand extreme temperatures, fire resistant, water resistant and chemical resistant, making it very fit for industrial use. Its elongation, high tear and tensile strength, provides flexibility and durability and can be formulated to have hardness range of 5 to 80 Shore A.

 

Partners in mould making (or tooling)

While LSR is fairly new to us, we have various partners in the industry who has been producing LSR moulds (or tooling) for many years. The tooling they make can be of two types – open nozzles and shut-off nozzles. The choice of which to choose depends on the quality requirement and specific use. Our mould makers produces moulds which can guarantee burr or flash free finished products.

How we can help you

We are able to manufacture any of your LSR products. Whether it is to manufacture high volume and high mix of different parts, and from various industries. We are happy to receive orders for a variety of products including: bottle nipples, electronic products enclosure (for eg. external storage drive), seals and gaskets, valves, watch bands, medical face masks, Laryngeal masks etc.

With our partnership with various LSR mould makers, we will be able to assist you from tooling to mass production from our facility in Penang (including our clean room) within a short period of time and other facilities in Johor or Hanoi, on-demand.

 


Contact us now to know more about Liquid Silicon Rubber or tell us more about your mass production LSR requirement.

Medical Injection Moulding: 5 Things to Consider

Many injection moulding suppliers today have the ability to provide manufacturing services to the medical industry. But, is there more than just having injection moulding machines?

We have summarised 5 key things to consider when choosing a medical injection moulding supplier for your medical components and medical devices.

1. Environment

Depending on the product requirements, having suitable environment controls are important. Certain products are required to be manufactured in a clean room (like our Class-8 clean room), some in a controlled environment whilst others can be manufactured in any normal factory floor. It is essential to define this when searching for a medical injection moulding service service provider as cost and quality may vary.

Class 8 clean room provides dust free environment

2. Validation process

The IQ (installation qualification), OQ (operational qualification) and PQ (performance qualification) process basically ensures that the the medical injection moulding process meets the quality acceptance criteria for the product. Whilst not all medical device requires this validation process, it is important to specify any requirement to the supplier up-front. This is to ensure that they understand the requirements of the validation process and provide adequate attention to this while developing the manufacturing process.

3. Certification of the medical injection moulding partner

When considering suppliers, have a look at their quality systems. the most basic ISO 9001 certification should be mandatory to ensure that the supplier has an adequate Quality Management System. Depending on your requirements, medical devices that require FDA approval or more stringent quality requirements, ensure that they have ISO 13485 and are up to date. Not all medical injection moulding requires ISO 13485, therefore be sure to tell your medical injection moulding partner the requirements up front.

4. Suite of capabilities

For most medical device manufacturers, it is important to ensure that their vendors are robust enough to have most processes in-house. This applies as well to the medical injection moulding vendor. While engineering skill-sets, like the ability to carryout design for manufacturability (DFM), mold / tool making and project management is important, also ensure that they have ability to do secondary processes. This includes having processes like liquid silicon rubber moulding (LSR), printing, ultrasonic welding and assembly. The less outsourcing, the better to ensure processes and quality is controlled.

5. Data

We cannot stress enough the importance to have data. Whilst traceability is part and parcel of ISO 13485, having a Manufacturing Execution System (MES) helps the capturing of data in a more autonomous manner. Having a stable Enterprise Resource Planning (ERP), Document Management System (DMS) and data security policy and procedures will greatly help ensure digital security, traceability and storage of documents. Hence, choose a vendor who is willing to invest in these systems to ensure that your supply chain management can be digitalize in the future.

Medical injection moulding with us:

  • Our plant in Penang, Malaysia is a certified ISO 13485 company and has a Class 8 clean room along with a control room. We have manufactured in this plant for the medical industry for over 10 years. We currently produce plastics for various medical equipment and single-use devices.
  • Our plant in Johor, Malaysia has manufactured plastic enclosures for medical equipment for over 5 years.

Contact us now to understand better how we can help you with your medical components.

Management Discussion & Analysis 2018: A Summary

An extract of the MD&A for 2018. Full version can be found here

OVERVIEW

The financial performance of Ge-Shen Corporation Bhd (“GSCorp”) was less than satisfactory for the year ended 31 December 2018 with a 11% drop in revenue to RM202.35 million and a 58% drop in Profit After Tax to RM4.52 million. In terms of Earnings Before Interest, Tax, Depreciation, Amortisation and Forex (“EBITDAF”) – the measurement of normalised cash generation GSCorp managed to turn in RM20.60 million which at a drop of 35% is a slightly better outcome than the Profit After Tax numbers would have suggested. Over the past year the operating environment has progressively been more challenging with the US and China trade war, slowing global economies and shorter product life cycle all playing a role in creating a more challenging operating environment. The cost of doing business has also increased through higher electricity charges as well as employment costs as wages and other mandatory charges has increased over the past year.

DISCUSSION ON COSTS

The past year has seen some material increase in our cost of doing business such as that of employment costs as minimum wages were increased together with an increase in the levy on foreign workers. Electricity was another cost component that has increased. The unfortunate thing about these cost increases were that it came at a time of lower revenues and because of the already thin margins that manufacturers are operating under, it has a disproportionate effect on the profitability of the company.

Hence going forward in 2019 the Management is focusing on cost management and in making the operations more efficient and to generate less wastage. We will be committing more capital to factory renovations and floorspace relayout to improve operational efficiency as well as the introduction of more robotics into the manufacturing process. We will also align our business development efforts to securing more value adding jobs.

CAPITAL EXPENDITURE

The Management believes that top line growth is something that we must pursue as if we don’t grow our capabilities, we will drift further way from the requirements of our customers, rendering us irrelevant very fast. Hence in this phase of GSCorp’s development, it is about resourcing up for growth through additions to the physical capital stock (i.e. land, building and machinery), additions to capability and processes (clean room and robotics), enhancements to the support systems (Enterprise Resource Planning System (“ERP”) and Manufacturing Execution System (“MES”)), and a commitment to build more customer linkages through more active business development programmes. We believe that in the short term, the period of the most extensive capacity building is almost behind us.

HANOI

The most visible aspect of our capacity expansion can be seen from the completion of the new factory in Hanoi, Vietnam. While there was a delay in the commissioning of the factory until August of 2018 against the earlier expectation of May 2018, this was still nonetheless very judicious in terms of timing as the area around Hanoi has seen a huge increase in activities as Vietnam is seen as one of the places which will benefit most from a possible relocation of the global supply chain away from China. With a brand-new facility to showcase and capacity to sell into a market needing capacity, we are confident that this new plant will translate into an important asset of GSCorp in the coming years.

PENANG

We have completed an ISO Class-8 clean room. Our clean room is outfitted with several specialised moulding machines and ancillary equipment to support our move towards meeting the manufacturing capabilities for the medical industry.

JOHOR

For the metal plant, the completion (of the purchase of factory) is necessary in order to facilitate the renovation of the plant for a dedicated metal stamping facility for a customer in the industrial sector. This is a new customer with much promise of higher volume parts, and we expect mass production to start in April with the arrival of new machinery. As for the plastic facility in Johor, we are relaying out the facility for a better aligned factory with potential for more automation and better work flow.

REVENUE

Revenue experienced a dip for the whole year (2018) and the bulk of the revenue dip occurred in the second half of the year when global economies turned from the coordinated growth to a coordinated downturn quite swiftly. This downturn in global economies was further exacerbated by the trade war between China and the US and these two factors contributed to the slowdown in the revenues of GSCorp. Sectors such as consumer electronics was particularly impacted with orders from several customers dropping off from the third quarter onwards and industrial products sector was also similarly affected as well. This is due to slower sales of the final product and the effect of inventory adjustment as principals sought to reduce stock through a decrease in ordering from their manufacturing suppliers like GSCorp. In certain products, principals have discontinued the running of certain models totally. The path to rebuilding the revenues is through an active business development programme.

BUSINESS DEVELOPMENT

Throughout most of 2018, Management has implemented a more comprehensive business development programme in order to complement the investment in the physical infrastructure space in an effort to grow. We have worked very hard to widen our network of customers as well as diversity in the sector exposure.

The role of business development is not just limited to having several sales persons on the ground to pick up leads, follow up on proposals and then having the lowest price on the quotation. The process of vendor selection is usually a long and sometimes torturous process as the principals assess the vendor’s capabilities in both hard ware and also engineering capabilities which is then audited before the engagement moves on to discussion on a particular part or model. In some cases, the manufacturer must also help the customer in interpreting their ideas into a product which can be manufactured efficiently without compromising on the quality of the product.

Therefore, having the right people to be able to deliver the solutions to our customers is key to the business development initiative. We are pleased to write that there has been some success in the business development side as we have been active in bidding for projects in all of our manufacturing locations.

US AND CHINA TRADE WAR

This trade war and the accompanying narratives surrounding it, is increasingly seen as something more fundamental and long term, therefore from a business rationale approach, supply chains which have traditionally relied on the manufacturing of goods out of China for global consumers is now being reexamined. At a minimum, there is a growing urgency amongst brand owners and principals to have an alternative supply chain to counter the effects of the tariffs. To preempt further disruption in the future, procurement teams have been busy scouring South East Asia for quality and reliable manufacturers to provide an alternative to China based manufacturers. As a quality manufacturer in the South East Asia region, GSCorp has been a beneficiary of this increased activity, however we must caution that while there have been a lot of early engagement, substantive success has yet to be recorded. While the actualization of these potential may take some time, we can however count ourselves lucky in having made the right investment decision of investing into more manufacturing capability as well as the increased efforts in business development thereby enabling us to be an active participant at this stage.

CONCLUSION

GSCorp as a component supplier into the global supply chain needs to build scale in the business as scale is essential for us to be able to cover more customers in different segments in order to achieve a greater diversity in end customers, scale is also needed to be able to offer more specialist engineering-based solutions to our customers in order to build a longer lasting and stickier relationship. This scaling up encapsulates the building up of manufacturing capacity and capability. The need to scale up is one of the most important matrices on our basic philosophy as it not just a permissive factor in our ability to grow but also an ability to derisk the business through diversification.

 


About Ge-Shen Corporation Berhad 
Ge-Shen Corporation Berhad (www.gscorp.com.my) is a contract manufacturer that specializes in plastic injection moulding, sheet metal fabrication and assembly services in 3 locations across South East Asia. GSCORP has years of experience helping product owners bring their ideas to life. It currently serves customers from various industries including the consumer electronics, household products, industrial, medical, automotive and aerospace. Ge-Shen Corporation Berhad is listed on the main market of Bursa Malaysia Securities Berhad.

We welcome any enquiries for our services. Please do contact us here.

Demand Options, a subsidiary of Ge-Shen Corporation adds additional factory space to increase capacities in metal stamping

JOHOR BAHRU, MALAYSIA: Demand Options Sdn Bhd (www.dosb.com.my), a custom metal stamping and sheet metal fabrication company, located in Johor Bahru, Malaysia has announced that it has increased its factory space by approximately 4,910 square meter by acquiring an adjacent factory building which is currently unoccupied.

“With the expansion of factory space which is adjacent to our current site, we are now planning to double our metal stamping capacity from 20 stamping presses to approx 40 stamping presses ranging from 25 tonnes to 400tonnes. The ability to scale up quickly puts us in a very good position to leverage on the current global trade displacement as we are able to offer competitive metal components to our customers globally. With this expansion, we are ready to help our customers to strengthen their existing supply chain by having sufficient and readily available capacities.” – Demand Options Sdn Bhd

Demand Options, is a subsidiary of Ge-Shen Corporation Berhad, has manufactured customized metal stamping and metal fabrication since 1997. Included in Demand Options’ capability is tool & die fabrication, prototyping, secondary processes like spray painting, powder coating and assembly. Demand Options has experiences in fabricating and stamping parts from 0.1mm to 5.0mm thick in ferrous and non-ferrous metals.

Renovation works in the newly acquired site has started and the first machines is expected to be delivered late April 2019. This newly acquire site is directly adjacent to its current site, which has been owned and occupied by Demand Options for over 10 years. The acquisition is highly advantageous as it allows Demand Options to scale very quickly without much duplication in headcount or supporting processes and facilities. 


(Photo: Building on the left, the newly acquired site, whereas the building on the right is the existing site which Demand Options has occupied for over 10 years)

Demand Options looks to expand its customer base in America & Europe and welcomes any enquiries for its services.

About Ge-Shen Corporation Berhad
Ge-Shen Corporation Berhad (www.gscorp.com.my) is a contract manufacturer that specializes in plastic injection moulding, sheet metal fabrication and assembly services in 3 locations across South East Asia. GSCORP has years of experience helping product owners bring their ideas to life. It currently serves customers from various industries including the consumer electronics, household products, industrial, medical, automotive and aerospace. Ge-Shen Corporation Berhad is listed on the main market of Bursa Malaysia Securities Berhad.


Contact:
Group Business Development Team
info@gscorp.com.my

Polyplas adds an ISO Class-8 certified Clean Room for Injection Moulding

PENANG, MALAYSIA: Polyplas Sdn Bhd (www.polyplassb.com), a custom plastic injection moulding and assembly services company has announced that it has received certification for its ISO Class-8 (FED STD 209E – 100K) clean room for the purpose of injection moulding and related manufacturing services.

“We are pleased to announce that we have just completed an ISO Class-8 (FED STD 209E – 100K) clean room in our manufacturing facility in Penang, Malaysia. This clean room has been developed specifically for injection moulding and supporting processes such as assembly, laser marking, ultrasonic welding, etc. We decided to develop and certify this clean room to meet the increasing requirements from our customers in the medical, precision electronics, aerospace and biotech industry. We are always investing and searching for new ways to better serve our customers and we believe that this clean room will bring added value for them.”

– Polyplas Sdn Bhd

Polyplas, a wholly owned subsidiary of Ge-Shen Corporation Berhad, has manufactured plastic components for over 30 years and has over 10 years of experience in manufacturing medical components and disposables with ISO-13485 certification. Currently, Polyplas manufactures for some of the biggest names in the industry, equally able to meet the different requirements for medical devices and consumables. With the added certified Class-8 100K clean room, Polyplas believes that it is able to provide its customers parts with significantly reduced risk of contamination by dust and other particles.

This certified clean room complements the existing control facilities at Polyplas, it has been carefully designed to take advantage of the experience gained in many years of manufacturing. A closed loop heat exchange actively manages dissipation of waste heat from the new electric Arburg injection moulding machines which prevents any turbulent air currents due to fans and hence less dust. Furthermore, raw materials and packaging are separated from the clean room to ensure less risk of contaminants.  The clean room is also flexible enough to operate additional processes such as laser marking, ultrasonic welding, sub assembly and printing in one line. 

Polyplas looks to expand its customer base in the medical industry with the clean room certification and welcomes any new enquiries for its services.

About Ge-Shen Corporation Berhad

Ge-Shen Corporation Berhad (www.gscorp.com.my) is a contract manufacturer that specializes in plastic injection moulding, sheet metal fabrication and assembly services in 3 locations across South East Asia. GSCORP has years of experience helping product owners bring their ideas to life. It currently serves customers from various industries including the consumer electronics, household products, industrial, medical, automotive and aerospace.

Contact:
Group Business Development Team / Louis Lau, Executive Director
info@gscorp.com.my / louis@gscorp.com.my

 

Transfer Your New or Existing Molds to Us

We understand that sometimes our customer have molds with other vendors or have already fabricated the molds with moldmakers and would like to find a partner to fabricate or mass produce your products. As a custom manufacturer, we accept mold transfer from various locations. As a experienced component manufacturer, we have assisted our customers with various mold transfer or project transfer projects. We work closely with our customers and become an extension of your engineering team, regardless whether you are a Original Equipment Manufacturer (OEM), Original Design Manufacturer (ODM), Contract Manufacturer (CM), Electronic Manufacturing Service (EMS) or a product owner. We will work closely with your team and establish detailed plans to ensure a seamless transition. So, if you are planning to outsource your in-house molding operations because you lack capacity, or if you need us to troubleshoot and solve an existing problem which you cannot solve, our experience can help you to speed-to-market. We can provide our engineering and tooling expertise to modify, repair or improve existing molds to meet your product requirements and ensure smooth delivery of products during mass-production.  
Have questions about how Ge-Shen can help with your mold transfer project? Contact us today to learn how we can help.

Design for Manufacturing (DFM)

Our customers find that getting our involvement during design stage promotes the manufacturability of the product and a more robust design is often the result. They also find that this collaborative approach is one of the best ways to improve engineering productivity and time-to-market because it avoids expensive, time-consuming downstream changes.



Our experience shows that decisions made during the design phase of a project determine 70%-80% of the cost of a new product. More importantly, decisions made in the first stages of a product design could determine the vast majority of the product’s cost, quality and manufacturability. We believe that by our involvement in your product’s DFM, we can assist you to ensure your product’s success and profitability.

With our DFM expertise, in-house tooling and the ability to design, we can help our customers:
  • Verify products and processes
  • Avoid unnecessarily tight tolerances
  • Design tools with easy mouldability, maintenance and consistent quality
  • Evaluate use of alternative materials
  • For Plastics, Mold Flow simulation analysis for a utmost mouldability solutions
  • Prototyping service to cater soft and hard tools to facilitate initial R&D requirements
As a manufacturer, we understand well the challenges of manufacturing. So, whether you are a Original Equipment Manufacturer (OEM), Original Design Manufacturer (ODM), Contract Manufacturer (CM), Electronic Manufacturing Service (EMS) or a product owner, we believe that we can help you reduce issues by going through the DFM process by involving us in the early stage of your project.

Our team in Hanoi, Vietnam, Penang, or Johor, Malaysia are capable in the DFM process. With our involvement during the design process, we can apply our more than 30 years of Design For Manufacturing expertise and experience to help ensure that your new products can be manufactured in a cost-effective manner. Our team can provide a DFM report for your plastic injection moulding, sheet metal fabrication and metal stamping components.
Have questions about how Ge-Shen can help with the smooth delivery of products during mass-production? Contact us today to learn how we can help.

Ge-shen is committed to upholding responsible labour initiatives

  • Human Rights We are committed to uphold the human rights of workers, and to treat them with dignity and respect.
  • Local Hiring We believe in prioritising the hiring of local employees in the location we operate, to boost the local economic growth, create jobs for the local community whenever possible and develop the local employee’s skillsets.
  • Diversity and equal opportunity We believe in diversity at the workplace including in race, color, age, gender, sexual orientation, gender identity and expression, ethnicity or national origin, disability, pregnancy, religion, political affiliation, union membership, covered veteran status, protected genetic information or marital status in hiring. Equal opportunity shall be given to people of diverse background to join and to continue building a career in GSCorp
  • Freely Chosen Employment We believe there shall be no force or involuntary labour, including the employment of minors or child labour.
  • Humane Treatment We believe that there is to be no harsh and inhumane treatment including any sexual harassment, sexual abuse, corporal punishment, mental or physical coercion or verbal abuse of workers; nor is there to be the threat of any such treatment.
  • Health and Safety We believe that health and safety standards, including safety gears shall be sufficient to protect the wellbeing of all workers. Safety training shall be organized to ensure that workers are competent and prepared for emergencies. The workplace shall be hygienic and workers shall have access to clean toilet facilities, sanitary water and eating facilities.
  • Performance Management We believe that each employee shall be given visibility on their performance and there shall be sufficient framework for employees to be accorded work targets that are linked to the overall Group vision.
  • Career Development Employees shall be given sufficient opportunities to attend training or develop their competencies and skillsets.
  • Wages and Benefits We believe that working hours, wages and benefits provided by the employer shall be reasonable and competitive.
  • Employee Engagement We believe that there shall be sufficient employee engagement programmes to ensure that employees have sufficient platform to reasonably voice grievances and make suggestions, while Management is able provide transparency and visibility to employees on the strategic directions, reward employees, and build Group culture