Examples of successes.

Washer Tank

Sometimes the initial results do not match the additional benefits.  On the Windshield Washer Tank Project, the molder was experiencing approximately $30,000.00 in losses on this part.  The project had been running for 8 years and had deteriorated to this point. Internal scrap was over 30% and customer PPM was near 100,000. This resulted in the molder being put on the No Bid list for future business.  We worked with the molder and the engineers at the Tier 1 supplier to make change to the physical characteristics of the parts and improvements to the mold.  Tooling costs were approximately $10,000.00.  Design and related engineering costs were $5,600.00. When the work was complete, the losses became a profit of $50,000.00 per year. Cycle time went from 48 sec. to 40 sec.  In addition, the molder was put back on the bid list just in time to receive the next generation Washer Tank and made a profit on the tooling of $175,000. They also built other small molds for initial tool build profit and additional profit on production.

Computer Printer

Sometimes the results are great but short lived. This molder also had serious PPM numbers and not only was on the No Bid list but was on the list to have work pulled. This was another project that required much interaction with the customers Engineering Department as there were many problems that could be solved by changes to the parts.  There were 3 main tools and many smaller tools that ran lower production.  On the high production tools the molder was able to do all of the tool work internally including all the Engineering Changes at an estimated cost of $5,000.00.  Engineering work including meetings with the Printer manufacturer was just under $4,000.00. In cycle time alone the savings to the molder was $.35 per printer and production usually ran approximately 200,000 per year.  Unfortunately, this project was up and running just long enough to get a pay back and then the entire assembly with all tooling was sent to Spain.  But there was potential for additional business on newer projects.

Washer Dryer End Caps

This was primarily a tooling problem.  The molder ran a 4 cavity family mold making PVC End Caps for a major appliance manufacturer.  Annual production was 750,000 or 375,000 shots per year.  After the mold had run 6 months, a cavity cracked and had to be replaced at a cost of $16,000.   Shortly after the first cavity broke, a second cavity also broke and had to be replaced. The tool builder contacted the material supplier and the heat treat company to get their assistance in analysis of the condition and come up with the root cause. No one from either company could show actual root cause but had their speculations.  After looking at the tool drawings and then the tool on the bench, within one hour the root cause was identified and a change to the mold was designed. The change eliminated breakage. If the life of a cavity was indeed 6 months, twice a year all cavities would need to be replaced at a cost of $128,000.00 per year.  Additional problem areas were investigated and working with the manufacturers Engineering Department, changes were made to eliminate other weak parts of the mold. Cost of the tool changes were accepted by the mold builder so the only cost to the molder was my trip and a few hours work.