Overview
With Insulo, a leader in technical foam solutions, we partnered with a prominent HVAC manufacturer to develop a groundbreaking gasket solution for display screens. This case study highlights our innovative approach, which resulted in a remarkable 92% reduction in scrap rate, positively impacting packaging, waste, and overall cost.
Challenge
The customer required a high-quality gasket to be placed between a display and their transparent cover, ensuring protection against dust and humidity. The conventional rectangular-shaped gaskets were effective but generated significant waste during production.
Solution
By leveraging advanced tooling and co-designing with the customer, Insulo developed a precision-engineered gasket that maintained the same high standards of quality while drastically reducing waste. This final solution was achieved after performing various trials to ensure optimal performance and efficiency.
Implementation
- Co-Design Collaboration: Worked closely with the customer’s engineering team to understand the specific requirements and constraints.
- Tooling Optimization: Invested in state-of-the-art tooling technology to enhance production precision and minimize material waste.
- Prototyping and Testing: Created prototypes for different trials and subjected them to rigorous testing to ensure they met all performance criteria for dust and water vapor protection.
Results
- Scrap Rate Reduction: Achieved a 92% reduction in scrap rate, significantly lowering material waste.
- Cost Savings: Reduced production costs due to decreased waste and improved efficiency.
- Environmental Impact: Minimized packaging and waste, contributing to a more sustainable manufacturing process.
- Quality Maintenance: Ensured the new gasket solution maintained the same quality standards, effectively protecting the display screens.
Conclusion
Insulo’s innovative approach and commitment to co-engineering solutions with our customers have set a new benchmark. This project exemplifies our ability to deliver high-quality, cost-effective, and environmentally sustainable solutions.