News and Events
Effective Problem Solving For Designetics Customers
A supplier for a major automotive manufacturer is losing money and having problems keeping up with production requirements needing to supply value added trim parts (Dow 43520A needs to be dispensed to trim parts for adhesion promoter pertaining to applications 3M 6381 two-sided tape.)
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Process Problems:
- Operator applies with a dauber and the cycle time is 25-35 seconds.
- The daubers are rapidly drying out.
- Streaking and insufficient coverage causes scrap and/or poor quality adhesion.
- Primer easily flow around a surface if not controlled.
- Labor and maintenance cost of $.475/part.
Solution/Results:
- Cycle time improved to 6 seconds per part.
- Higher quality parts and substantial savings per year.
- Lower scrap levels and adhesion problems.
- Current labor and maintenance part cost of $.166/part.
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In the past, manufacturers have used daubers and/or brushes to apply quick cure promoter fluids. This application method was creating a plethora of issues such as high cycle times, labor costs and increased scrap rates to name a few.
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Process Problems:
- Requirements increased for the material to be applied to the top, back and edges of automotive glass.
- Focus was placed on new issues such as a defined and crisp edge line for the growing importance placed on aesthetic characteristics.
- Cycle times of 30-50 seconds were desired instead of the current 2-3 minute cycles.
- Scrap rates were exceeding 50%.
Solution/Results:
- Designetics an expert in dispensing moisture cure promoters and primers developed a line of wrap-around applicator tips.
- Saved the glass manufacturers thousands of hours in labor costs.
- Dramatically lowered quality issues.
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The application of low viscosity materials to the substrate has created problems of being 3-4 times thicker on the edge than in the center. This is referred to as "snow plowing."
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Process Problems:
- Snow plowing creates issues such as:
- Adhesion failures
- Uneven curing
- Aesthetic issues
- The specifications of many primers and coatings require .0003-.001" thickness for a proper application.
- The edge line must be defined and crisp since it is visible to the customer.
Solution/Results:
- Specialty designed applicators with a "flow hole" for even material lay-down.
- The "flow hole" design reduces and controls the normal force on the applicator.
- It helps to create crisp and defined edge lines.
- Keeps the dispensed film build within the proper thickness requirements.
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