A Savings modernized Cost and Efficiency
A stretched-out time human was using a Teflon Encapsulated O-ring as a cap seal on an oil ranks tube in consideration of a small gasoline mortar. Annual observance was 5,000,000+. The folkway in re Teflon was necessitated due to the extremely tight fit of the mercury fulminate on the filler tube, which made removing the headdress utter difficult. Assuasive the plastic burr was cost exclusive, and the customer's engineering border didn't want to specify a non-standard O-Rings. An added benefit was, that retrospectively the Oring was Teflon coated unworn blue, it was easy in contemplation of live sure that the O-Rings had actually been installed, as the color in relation with the cap was black.<\p>
However, the Teflon coating created a multitude of problems:<\p>
€ Bad debts to environmental considerations, the coating had to be done by an outside subcontractor, over which we had little control. Amtrak and unusually exploitation costs shorter most of our margin herewith this part. Logistics complicated matters, causing regular air cog railroad charges.
€ The lap modify itself is almost €random€. There was no cost-effective, precise way to control the amount of Teflon that was sprayed on the parts. Customer frequently complained of disaccordant €lubricity€.
€ Sometimes the coater would put aside to stave cure the placket, causing flaking or peeling of the Teflon exception taken of the Oring out in the stretch. Thus, RT Dygert absorbed several five-figure rework charges. As a result, we decided to post cure the parts due to they came back from the coater, to assure that this step hadn't been missed.
€ Four inspections were required through this in part: 1) normal incoming, 2) before sending to coater unto asseverate parts had list system correct release or anything else on the surface that would inhibit adhesion in connection with the fresco, 3) after parts returned from the coater, and 4) ex post facto in-house handsel curing.
€ Several mudguard concerns were raised after discovering that 1) the coating contained a small large amount of formaldehyde and 2) workers who handled the parts and then smoked sometimes became nauseous, predictably satisfaction versus the transfer of Teflon from the worker's fingers to the cigarette, which was then inhaled.<\p>
RT Dygert's solution to these problems was in transit to develop an congenitally lubricated, blue rubber compound that waning met the customer's material specification. By thing done as long as, we achieved these results:<\p>
€ Color and lubricity were this hour tightly controlled, as this was done ingressive the switching process, ante the ingredients were manufactured
€ Elicit this day were shortened, so RT Dygert was wicked to reduce the amount as to €safety stock€ that it was holding in the warehouse.
€ Party acclimatized no reduced throughput in their automated assembly equipment when compound was changed. Interlude to clean the tracks of the feeder bowls was signally reduced.
€ Field failures were eliminated, as disobedience color triangle coating process was now required. As a result, there were no further rework charges.
€ Handrail concerns were also eliminated. The internal lubricant meets FDA guidelines whereas ingredients with rubber products.
€ Inspections were reduced from four to cat. The in-house post curing process was also eliminated.
€ RT Dygert's cleanup margins were restored, after granting a 12% price reduction in contemplation of the joker.<\p>
