Process technology evaluation

•  Problem / Situation:

The client’s urethane foam molding process was beset with variability resulting in unacceptable productivity and extended setup times. There was considerable tinkering with the process from day to day and process conditions for the same product were not always consistent which resulted in varying product quality and inconsistent productivity.

•  Solution and Approach:

A complete process assessment and evaluation was undertaken with the objectives of understanding the details of the operation; identifying operational deficiencies and establishing recommendations based on best practices and industry standards.

The assessment and evaluation was broken into eight process categories such as the molding injection equipment, chemical distribution system, chemical process conditions and handling, process control and documentation, utilities, preventive maintenance and safety.

The assessment and evaluation strategy required considerable observation of the production process, extensive calculations to verify engineering designs, and interviews conducted with internal personnel and external suppliers.

•  Results / Outcome:

A closure meeting was held with the client upon completion of the data gathering and assessment to discuss preliminary results. A comprehensive report was then published detailing the analysis of all systems and recommendations for changes. For example, an energy balance done on the hydraulic and chemical distribution systems identified severe design limitations which were directly impacting on process consistency. Subsequent review with the client resulted in an initiative to begin adopting the recommendations in phases of importance and ease of implementation.