Case Studies
During our many years working within the manufacturing sector, we have served hundreds of customers, from the major
auto manufacturers to small start-up companies operating out of a home garage.
Here is a typical example of how we serve our customers with
creative and innovative solutions to their design and decorating problems.
Case Study: Going the Extra Mile to Serve Our Customers
Problem: Building the Better Box
A Wall Covering Manufacturing Group was looking for a
new way to creatively provide sample swatches of their products to their
clients, which included Interior Designers, Architects, etc.
Their idea was to create a decorative box to hold insert cards that the samples would be attached to.
These card were to be produced by another company.
The container they
envisioned needed to perform the desired function of housing the swatch
cards with some sort of clip to secure them.
The customer did not know exactly what
they wanted other than knowing it needed to be distinctive and impressive in
design, and it needed to be very durable, a key criteria because the box would probably be transported frequently.
After being turned away by a number of other injection molding companies,
they contacted ACM upon finding our web site on the internet.
Solution: Thinking Outside the Box to Create the Box
During an initial phone conversation, our Cost
Coordinator Larry Maltsberger got details of their initial ideas and
provided an overview of plastics and how injection molding worked. Without
getting into specifics, he was able to provide a ballpark idea of what
the project might cost.
They then sent us a sketch of their original idea, which was considerably
different than the design Larry had envisioned. Our design team, always up for a challenge, agreed to meet with
the client to discuss possible solutions.
At the first meeting at our facility in Indianapolis, we finalized a
design concept, selected the correct plastic for the product, and discussed
the various options available to decorate the piece, including silk
screening, pad printing and hot stamping.
After that initial meeting we were able to provide a more accurate quote of what the
project would cost. We also had two or three meetings with the group manufacturing the swatch cards
for the inside.
Basically, to build their confidence, we developed their project without
receiving any payments. They were impressed with our abilities when we
presented them with a clear picture of their project based solely on their
concept ideas.
Execution: Finding the Right Solution for Your
Project
We had a prototype built to provide something they could actually hold onto and touch. From that point, we developed a tool and ran some sample parts.
We had
samples of the different decorating options produced on plain pieces of plastic so the
client could see what each process looked like.
After evaluated the different decoration processes, the customer was not
satisfied with any of the choices. We continued
researching alternatives and determined that in-mold decorating might be an
excellent choice for this project. We showed them a sample part that incorporated the in-mold decorating process, which they
agreed was the best option.
In-molding decorating
was selected because it was by far the best looking, although not
the least expense, method we showed them.
Their clientele,
including Interior Designers and Architects, are very discerning and not-easily-impressed,
which is why they chose aesthetics over saving time and money in this
instance.
Coordination & Cooperation: Key Elements of a Successful
Design and Manufacturing Project
We then contacted the company that manufactures the in-mold inserts to
coordinate the various aspects of the project. Their group did an excellent
job of coordinating the whole project. We had very open discussions
regarding logistics on our end, and that of the sample card makers, to make
it all happen.
Working in cooperation with both the sample card manufacturer and the
insert maker, we came up with the solutions needed to develop the whole project. The engineering of the
end-product was a real team effort between the customer
and the various manufacturers.
The
manufacturer of the insert overlays for the in-mold decorating had not
previously used
this application on such a large scale. With assistance from ACM
engineers, they combined processes used on other projects and applied a new variation to a bigger product than
they had previously worked with.
As it was a new application development process
for them as well, it was a win-win situation for everyone. ACM is now able
to offer this new in-mold stamping process to our customers for a wide range
of applications.
Results: Proof of Our Abilities is the Customer's Satisfaction
The end-to-end full service we provided this customer is indicative of the scope of our ACM’s abilities.
- We provided the design service for both pieces of the box (the brown walls and the green bottom made via straight injection molding process)
- We developed a prototype
- We were able to offer multiple printing options and samples
- We provided project coordination in some areas, and were able to be easily directed in areas coordinated by others
- We provided basic education in the plastics process to the customers
to successful initiation them into the world of custom manufacturing plastics
- We are also performing secondary operations, including:
- De-gating the parts
- Cutting the handle
- Assembly - heat staking of top and bottom sections of box
- Final packaging
This client had a project with a specific use and purposes, along with a
budget based on the the value they felt this product would bring to their
marketing efforts.
If you have a similar type of project in development, or just a concept
and would like to develop it further, you can learn more about the process
and the type of information we would need you to provide at
Quotation Process.
For a quote or more information about how we can help your project,
call Larry Maltsberger, 765-457-8225, ext. 13, or send us an email, or submit this short form:
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