3 Million in 3 Months?
A production task was set to the group to explore how we could adjust the injection moulding process in order to facilitate the production of 3 million units of the ski pole holders in 13 weeks.
Many test injections were iteratively carried out to determine the best pressure and speed at which the plastic should flow into the block. Each test injection was timed and compared based on the amount of flash, shrinkage and warp.
13 Weeks to make 3 million widgets
576,000 Manufacturing seconds per week
576,000 / 8.33 Seconds = 69,147 injections per week
69,147 X 13 = 898,911 widgets in 13 weeks per mould
In order to achieve the 3 Million target the mould block was redesigned to inject 4 widgets in one cycle.