Quality isn't negotiable at Caplugs. We've built our entire operation around the principle of consistently delivering quality products to our customers—meaning each product that leaves our Buffalo, NY manufacturing facility needs to meet exacting standards.
We're able to live these lofty goals of an unwavering focus on quality through experienced team members like our Quality Team Expert Al S., who has spent two decades ensuring every product he touches meets our stringent quality standards.
“I’m always looking out for the customer,” said Al. “That’s always at the forefront, whether I’m working on a vinyl, molding, extrusion or hose protection project, it’s everything really.”
As a quality team expert, Al is a part of one of the most critical operations at our facility, ensuring tools are set up for success and that parts are reaching their desired outcome for the customer.
“Basically, I’m looking for a few things—calibration and validation,” said Al. “Calibrating is making sure the tools that the toolroom or maintenance teams will be using (like calipers and micrometers) are working properly and that we’re setting them up for success. The validation side is measuring—when a customer starts a project and they have a part they want to manufacture, I’ll be measuring the part and making sure everything is in order before things go into production.”
This dual focus represents the backbone of Caplugs' quality assurance process. Without properly calibrated tools, even the most skilled technicians can't deliver accurate measurements—a reality that could compromise entire production runs and customer deliveries.
The validation process is equally critical, serving as the final checkpoint before full-scale production begins. By thoroughly measuring and verifying new parts during the validation phase, Al helps prevent costly production errors and ensures that customer specifications are met from the very first part produced.
“It's about catching potential issues before they become real problems,” Al explains. “Over the years you learn to look for certain things, and I feel pretty good when I catch those little errors before they become bigger issues. Parts may look a little defective, or have a little bit of flash on them, that an untrained person may not notice. It’s moments like that when it feels like I'm making a difference.”
Other issues that Al typically discovers during the validation stage include non-fill (pieces of plastic missing from the part), pressure burns, doubles, and something as simple as the wrong color being used.
“All these different defects I need to point out, so you really need to pay attention to detail,” Al added.
While Al is now seen as our resident quality expert, he is sure to credit those who have come before him for the good habits and knowledge he has picked up along the way.
“Some of the people that I’ve worked with over the years really taught me a lot,” said Al. “A lot of 20-30 year vets that weren’t afraid to show me the ropes. If I didn’t know something when I first started out in the quality department, I didn’t hesitate to ask, and that really helped me learn the nuances. I’ve always had a good team around me, I learned from them and kept that same process of quality over the years.”
A project from several years ago is the perfect example of Al’s dedication and meticulous approach—and something that still sticks out in his mind to this day.
“Years ago, I worked weekends, and my manager had a large VDM (vinyl) project he wanted myself and a teammate to start on,” Al said. “It was roughly 1,000 measurements or validations that needed to be completed. Nothing super hard, it was standard measurements, but we took it upon ourselves to give it our all and get the project completed over the weekend. I still remember it because we got it done, and it was something our boss probably didn’t think we’d accomplish in that short period of time. That’s something I’ll never forget.”
Al’s hard work hasn't gone unnoticed, with him recently being promoted in the spring of 2025, just a few months before his 20th anniversary with the company, which he will celebrate this summer.
“Caplugs has given me an opportunity to grow within the company, every department has been really solid to me,” said Al. “I’m just trying to make a difference for the company and learn as much as I can. The sky is the limit from here.”
We couldn't be prouder to have dedicated team members like Al who put quality first in everything they do. His attention to detail exemplifies the values that drive our Buffalo, NY manufacturing facility’s success.
With experienced quality experts like Al leading the way, we continue to set the standard—proving that when you truly prioritize quality, success follows.
Thank you, Al, for all that you do!
Caplugs has a comprehensive quality management system and the latest technologies in testing and measurement equipment to provide consistent quality. Our stringent quality management systems ensure the necessary process controls exist to provide our customers with consistent, quality products. Learn more on our quality standards page.