What Happens When You Need To Mold Injection Plastic Better, Faster and Meet Offshore Pricing?
The Project
- Multi function commercial soap dispenser
The Issues
- Product designed and tooling built off shore, creating flaw and inconsistent quality in product produced off shore
- Off shore supplier could not react quick enough to demand for higher volumes and consistent quality product
- Off shore supplier could not react to, or understand required design changes in timely manner
The Solutions
- New design for multi cavity mold provided to meet increased demand and future production requirements
- Production delivery cycle reduced from 120 days to 30 days
- Design changed to offer increased product variations from one mold. Four new product offerings were now available
- Design changes were completed in 2 weeks
- Value added assembly set-up at press side to reduce final assembly labor requirements
The Results
- Base production increased from 20K units a month to 50K+ units a month.Base production increased 50% because product was more available and of good quality
- Distribution channels returned to full capacity
- Reduction in overall cost of completed assembly dispensers with a reduction of lead time by 2/3