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10 MoldMaking Technology —— MARCH 2018 Profile Image courtesy of Master Tool and Mold Inc. How do you manage workflow 24/7 with 10 employees working one shift? Jim Sperber, president: At Master Tool and Mold Inc. (MTM), we do not run automation, but all of our machines can run multiple tools and multiple programs unattended through the nights and weekends. Our ability to react quickly and efficiently to our customers' needs is key. I tell customers that if they call me at 5 a.m. on any day (except Sunday, when I am at church until 9 a.m.), I will be there within the hour to pick up a job, and we will be ready with any parts needed to dive into the job and get it done. Also, MTM is fortunate to have a great team of dedicated employees who have a wide array of skills. Cross-training is essential. Our moldmak- ers are highly skilled CAD operators, designers and program- mers. They know how to run the EDM and CNC machines, grinders and other equipment, they can polish tooling, and they are always willing to extend their skill sets to include new advances in the field. We call it great teamwork because our employees train each other without a formal training program in place. The team is routinely updated on the latest Solidworks and PowerMill software through training, and we 765 N. 11th Ave. P.O. Box 152 Grafton, Wisconsin 262-377-8030 mastertoolandmold.com • Was founded in 1972 by Lyle Sperber, father of current owner and president Jim Sperber, who purchased the business in 2005. • Is based out of a recently expanded, 10,000-square-foot facility with 10 full-time employees. • Builds plastic injection molds and diecast dies and offers part and mold design, sampling and "extremely fast and precise repair work." • Builds molds for the medical, housewares, lawn and garden, automotive, recreational and plumbing industries. It's all about family, family values and a versatile, cross-trained team at Master Tool and Mold. Family includes the shop dog, Donuts. Here, company President Jim Sperber and his daughter, Kat Froehlich, flank a large mold that the company's team of 10 built using OKK CNC machining centers that run 24/7 without automation. A Conversation with … Master Tool and Mold Inc. regularly send them to American Mold Builders Association (AMBA) conferences, webinars and vendor classes and dem- onstrations to learn the latest technologies. At an AMBA conference in 1994 and 1995, for example, one of the keynote speakers said, "High-speed machinery, controls, programs and software will change. Iron won't change, so buy a good chunk of iron." This was a pivotal moment. From then on, we were committed to quality iron and machinery, particularly OKK machining centers. Additionally, we expanded our building by adding 4,000 square feet in the third quarter of 2015. This made it possible to add several new machines, including an OKK VR76 vertical machining center equipped with a Mitsubishi M830 control (the first control like it in the United States at the time). We purchased cranes that can lift heavier molds and workpieces than what we previously used. With our new capabilities, we can build a 32-cavity unscrewing mold, a 20,000-lb. stack mold, and a single-cavity prototype mud insert, all while keeping up with our daily, and sometimes hourly, repair work (which we pick up and deliver) to keep our customers up and running. Does MTM have a special, niche market? Sperber: Our niche is that we do not have a niche. We focus on whatever our customer is focusing on, and that provides for a diverse customer base. If we can lift it, we will do it. No is not an option. Most shops target a specific type of work, but we target a specific type of customer—a customer who does a great variety of work. That's where the variety comes into play. Our ability to run constant repairs fills in all the