Consolidating Assembly Operations For Custom Molded Plastics Throughput Increases

The Project

• Cost reduction, quality improvement for garage door component

The Issues

• Thick walled frame with multiple secondary operations in manufacturing using a extruded part
• Frame in extruded form had to be glued together and then sent out for painting
• Lead time and delivery

The Solutions

• Convert approach to custom injection molded frame in one piece
• Eliminated the gluing process used with extruded product
• In molding process colored resin was used to eliminate the need for frame to be sent out for painting
• Injection molding tooling was made to allow for multiple inserts that allowed for different door thickness and colors

The Results

• Cost savings in the way of material and painting function.
• Provided savings in material costs, labor for gluing and painting, plus transportation costs in sending frame out for painting
• Better quality product with better stability and color tones
• Eliminated a issue at the customer that was consuming engineering resources