How Education and Training Saved $2.4 Million: A PT&E Program Success Story
In the manufacturing world, scaling production usually comes with a substantial financial commitment. The prevailing assumption is that to triple output, a company must triple its staff or invest millions in new machinery. However, the most valuable resource on the shop floor is your team’s knowledge.
Matt Funke, a Mechanical Engineer at Schweitzer Engineering Laboratories (SEL), proved this hypothesis. By investing in the right education and training, his team achieved $2.4 million in savings and a significant boost in productivity without adding a single new employee.
The Challenge: The Outsourcing Cost
Like many manufacturers, Matt Funke and his team at SEL faced a critical issue. Their five-person toolroom was struggling to keep pace with increasing demand. With a capacity of only 13 new molds per year, their team was forced to make costly outsourcing decisions to meet production schedules. While the work was completed, margins shrank, and reliance on external vendors grew. Matt realized that he did not necessarily need a larger team. He needed a team equipped with the right education and training.
The Solution: The PT&E Program
Matt attended the American Injection Molding (AIM) Institute’s Plastics Technology & Engineering (PT&E) Program. The PT&E program is designed to bridge the gap between mold design, processing, and materials. The curriculum focuses on actionable, scientific applications on the shop floor rather than purely theoretical concepts.
The Results: 285% Increase in Output
After completing the program, Matt immediately applied his education and training to SEL’s approach to mold design and manufacturing. With the same five-person team, SEL achieved the following:
- 285% Increase in Output: Production jumped from 13 to 50 new molds in a single year.
- $2.4 Million Saved: Outsourcing costs were prevented by bringing work back in-house.
- $300,000+ in Cost Savings: Direct savings were realized by molding parts in-house rather than purchasing them.
Real Money, Not Just Estimates
“That’s real money, not just an estimate,” says Matt Funke. “The education and training provided by the PT&E program have played a large role in how we design molds for faster manufacturing that run the first time they are set up!”
By understanding the science behind the process, the SEL team transitioned from troubleshooting errors to designing for success. They achieved “first-time right” setups, drastically reducing cycle times and waste.
Take the Next Step
Matt’s story at SEL is a result of what occurs when engineering teams are provided with the world-class education and training required to optimize their resources.
We are currently accepting registrations for our upcoming Plastics Technology & Engineering (PT&E) Program.
- Start Date: April 13th, 2026
- Availability: Seats are limited.
Need Help with Funding?
Federal and state grants often cover employee education and training costs. Please contact us to learn more about funding opportunities to maximize your ROI.
Contact Us Phone: (814) 899-6390 or Contact Us Form.
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