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SUCCESS STORY

Plastikos, Inc

Lean Bronze Certification Fuels Teamwide Momentum

Plastikos, Inc., headquartered in Erie, Pennsylvania, is a precision injection molding leader serving highly regulated industries such as medical devices, electronics, and aerospace. With advanced cleanroom capabilities and a team of RJG Master Molders and degreed plastics engineers, Plastikos is known for its commitment to innovation, quality, and workforce development. The company fosters a culture of operational excellence, continuously reinvesting in its people, technology, and processes to stay competitive in a global market.

  • The Challenge

    As Continuous Improvement Quality Engineer at Plastikos, Molly Miller works across departments to support efficiency and quality. With a background in plastics engineering from Penn State Behrend and prior experience at
    Honda’s Marysville Ohio plant, she was no stranger to lean concepts. The company’s Molding Managers saw her potential to lead improvement initiatives. Molly said Plastikos has always had a mindset of cleaning and organizing, but they wanted to align everyone around visual cues, standardization, and shared language.

  • The Solution

    Molly looked to NWIRC’s Manufacturing Excellence training that would lead to preparation and testing to receive an SME Lean Bronze Certification. The course is facilitated by NWIRC’s Operational Excellence Specialist and includes five morning sessions with additional days for test preparation and taking the exam.

Metal Background

Client Success

Molly earned her SME Lean Bronze Certification in late 2024 and returned to Plastikos energized – but not alone. Her enthusiasm helped spark a wave of continuous improvement, but it was the company’s collaborative culture that turned ideas into action. Molly helped formalize Plastikos’ 5S efforts, but credits the success to broad buy-in from managers, supervisors, and frontline staff. “The class gave me the tools to not just have things make sense in my head, but to also teach others,” she explained. “It expanded my comfort zone and gave me the confidence to lead lean projects across departments— not just in quality.” One of Plastikos’ first initiatives was launching a 5S champion and implementation team, with each area of both plants represented. Together, they conducted Gemba walks, identified inefficiencies, and implemented improvements. Projects ranged from reorganizing operator tables with visual tape indicators to shadow boxes for gauges and tools. “Our gauge cabinet had items all over the place,” Molly recalled. “We worked with our automation team to 3D print shadow boxes for each gauge and fixture.” While Molly’s Lean Bronze training gave her new tools and confidence, she emphasizes that the real impact comes from shared ownership. “The class helped me articulate ideas and guide others,” she said. “But it’s the team that makes it work. Once one person gets excited, it builds momentum.”

For anyone considering the Manufacturing Excellence course and achieving SME Lean Bronze Certification, Molly shares this reflection: “You get to see theory and practice. It pushes you out of your comfort zone—and then expands it. You learn how to ask the right questions, guide others, and show the benefits of change. And, last but not least, you make connections that last well-beyond the course – even with the instructor to lean on as a resource moving forward.”

Download the Plastikos’ Lean Bronze story here.

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