Wisconsin Plastic Products uses Polymer Science coupled with design of experiments methodology to produce a game changing product for the retail display industry.
The Problem:
The customer was struggling with costly product liability claims and unreliable living hinge performance using their existing product design and extruder.
Manufacturing Details
MATERIALS USED:
RPVC
Thermoplastic Urethane
The Attack Plan:
Plan Definition
Wisconsin Plastic Products works to lay out a multi faceted approach that includes a shift in polymer grade and living hinge designs expected to optimize performance.
Execution
Wisconsin Plastic Products builds three prototype extrusion dies to be performance tested focusing on living hinge variables of durometer, thickness, and length.
Performance Testing
Wisconsin Plastic Products quality uses the design of experiments methodology to test each extrusion batch for effective bend cycles prior to failure. Results are evaluated and shared with Wisconsin Plastic Products engineering.
Execution
Wisconsin Plastic Products engineering uses preliminary cycle testing data to create a final extrusion design optimizing each control variable. A pre-production extrusion trial is executed for further performance evaluation. Wisconsin Plastic Products quality rigorously cycle tests and gather positive results exceeding customer demand. Quality signals a “ go” to mass production.
The Solution:
Wisconsin Plastic Products optimizations to material choice and living hinge design yield a product that exceeds it’s customer’s expectation. Product liability claims shift to zero and no performance issues are logged since mass production launch.
Manufacturing Details
MATERIALS USED:
RPVC
Thermoplastic Urethane