International Appliance Manufacturing 2008 - (Page 9) Example 3: The image to the left shows ‘freeze time’ through the part thickness of a housing for an appliance motor and power train. In this example, analysis identified an excessively thick section which would add 54% to the injection moulding cycle as a result of prolonged heat dissipation time. Eliminating this problem produces significant cost reduction. Post moulding distortion will also be significantly reduced: a development factor with major implications for cost and lead time to product launch. represents 50% of the part cost will reduce the total part cost by 2.7% when energy costs are also taken into account. • The moulding cycle time advantage achieved by eliminating thick sections will further reduce labour and energy costs, delivering a total part cost saving of 5.1%. A brand that consistently optimises its components - and therefore its processing costs - delivers a virtuous cycle of competitiveness. Total business overheads are optimised over time, adding further cost down leverage to the principle processing savings. Example 4. over the page demonstrates the elimination of avoidable cost. Without early phase intervention, development costs would accumulate as follows: • Because issues will arise after tool trialling, finding the root cause solution will be expensive in terms of time and tool modifications. • Alternative process conditions to optimise performance may be tried. If the problem is marginal, the processor may deliver a working component but the life cycle of the product will be hampered by a small process window, with all the associated cost implications of quality, m/c attention, sub optimal PPM performances and unnecessary management attention. If the problem is not marginal, then the whole investigation will waste time and money, both for the Brand and for the manufacturing partner. • Alternative materials may offer a solution. However these are usually more expensive as they are formulated to achieve very specific performance parameters. This is often successful - but upgraded materials saddle the product with a lifetime burden of unnecessary cost. Experience has shown that the development cost drivers described above can represent 10% of the total tooling cost for a programme. These costs are usually unbudgeted, which leads to a ‘who pays?’ debate. The Brand owner must also absorb additional, unbudgeted development costs incurred in its own team. And importantly – planned launch dates are likely be missed by weeks or even months, which may have incalculable longer term market effects for the Brand. Conclusions Modern appliance manufacturing places new pressures on brand owners and their manufacturing partners. Knowledge of injection moulding must now be fused with a huge range of technical, analytical and economic competencies – and a global footprint to accommodate logistics and cost-down planning. But how can a so-called ‘solution provider’ accumulate expertise International Appliance Manufacturing 2008 9
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