Applied Mechanical Engineering Expertise

To Improve Productivity and Profits

AUTOMATE HIGH VOLUME CONSUMER COMMODITY
(FORTUNE 500 COMPANY)

Problem: Arch Rival of our Client, another major manufacturer of writing instruments, introduced ballpoint pens with stainless steel ball sockets instead of the usual nickel plated brass. Nickel-plated brass would wear out prematurely when mated with jumbo ink reservoirs. Our Client started losing market share and hired us to develop a stainless steel socket point with at least equal life and writing quality.

One of the client requirements was that we continue using their own ink (manufactured by our Client). This ink was considered as inferior to the ink the Arch Rival obtained from an outside supplier, however it was less expensive to use. Because of this requirement, the Arch Rival socket could not simply be copied.

Test data on all competitive products were available as reference. The processes involved wire feeding, cut-off, deep step drilling, high precision internal and external machining, assembly and cold forming. Tolerances of +/- ten millionths of an inch were required. Rate was 40 point assemblies/ min./ machine.

Solution: We developed a new, simpler socket design that eliminated one process step. Developed the production methods and tooling. The result was better process control with writing quality superior to all competitors. Market share climbed over 50%.

DEVELOP CONSUMER PRODUCT
(FORTUNE 500 COMPANY)

Problem: Design a superior hose-end garden sprayer, embodying two precise chemical-to-water ratios.

Solution: Design submitted and approved. Met all specifications on time. Parts were injection molded Delrin and blow molded Surlyn. Became the premium model sprayer for this Client.

FREE ADVICE SAVES SNACK FOODS COMPANY BIG BUCKS
(FORTUNE 500 COMPANY)

Problem: Client was packaging popular snack food in rigid container with corrugated paper liner to protect product from handling damage. Asked us to show them how to automate the production and installation of the liner.

Solution: We asked a simple question they had failed to consider: Is the liner really necessary? They tested product without liners and found the liners unnecessary! Big savings - no fee from us.

Problem: Medical specialists recommend sitting with the legs elevated as an aid to relaxation, circulation, reducing pain and swelling from injury or surgery, etc. The legs must be elevated at the proper angle to produce the desired results. However, no convenient means to do this existed. Ottomans and expensive recliners don't meet the criteria. One had to put books, pillows or whatever on a table or chair to provide the required angle.

Solution: We developed a convenient, comfortable and inexpensive leg rest, called THE LEG SAVER which meets all the criteria when used with any chair or sofa. It is being recommended by doctors, therapists and trainers. For more information visit the web page at http://www.vsh.cape.com/~djames.

DEVELOP PROCESS & MACHINERY
(SMALL COMPANY)

Problem: Small Company (our client) and a Giant Corporation shared the market for citrus fruit processing machinery about 50-50. The processing machines are leased to the producers. The demand for peel oil, a by-product, became equally as important as the juice products.

Major market customers started to demand high quality peel oil from their machinery lessors. Giant Corp's machines employed a concept that produced high-grade peel oil simultaneously with juice extraction. Our client had no means for producing the oil.

A crash program was started to develop suitable machinery to meet the major market customers' requirements. Without such capability, Small Company would not only miss out on the additional revenue gain from the oil (100% increase) but would be 'thrown out" of the major market customers' plants and replaced with machines from Giant Corp. The net result could put Small Company out of business.

Solution: The resident Engineering Manager at Small Company wanted to modify an ill-conceived oil extractor acquired from a former small competitor. Our analysis showed this approach could not produce a viable machine and that it was necessary to start with a clean sheet of paper to meet the customer's specifications.

The President elected to take two parallel courses of action. The resident Engineering Manager and staff went their way and we went ours. Guess who won?

We produced a simple machine to extract the required oil quality and yield. A by-product was cattle feed which Giant Corp. couldn't match. Small Company was able to maintain the 50 - 50 market split and enjoy the increased oil revenue. Several patents resulted.

AUTOMATE ELECTRONIC PRODUCT MANUFACTURING OPERATIONS
(FORTUNE 500 COMPANY)

Problem: Provide equipment to straighten leads, print logo & part number, and package solid state components in trays, then stack trays for cartoning. Rate required was 3,000 parts/hr., requiring 1-second ink curing time.

Solution: Employed commercially available feeder/singulator, lead straightener, printer, and UV ink curing light source. Designed unique simple, reliable part feeding, tray loader, and stacker.

PACKAGE MEDICAL PRODUCTS
(SMALL COMPANY)

Problem: Collate and carton small plastic packages containing a single contact lens at a rate of 10,800/hr.

Required quick changeover from 6 packs/carton to 3 packs/carton. Pack label had to face carton opening. Note: Blister pack collating requires alternate packs to be rotated 180 degrees or inverted to nest packs to achieve minimum carton size.

Solution: Facing many unusual challenges, we custom designed an appropriate machine. This machine was produced on time and met all criteria, at a fraction of the cost and space of existing collators. Controlled by PLC. Utilized commercial cartoner.

AUTOMATE ELECTRONIC PRODUCT MANUFACTURING OPERATION
(SMALL COMPANY)

Problem: Replace manually operated machines for milling pogo pin components with automatic machine.

Solution: Designed and built simple, PLC controlled machine that met all criteria.

PACKAGE CONSUMER PRODUCT
(MEDIUM SIZE COMPANY)

Problem: Package blister packed utility knife blades in form-fill-seal carton.

Solution: Custom designed machine, met all criteria. Unique flap tucking mechanism had to be created to meet space limitations. Employed commercial hot melt gluing equipment.

AUTOMATE SEMICONDUCTOR MANUFACTURING SYSTEM

Problem: Develop an automated pilot plant for the production of photovoltaic solar cells and panels to reduce cost by at least 80%. Pilot plant to serve as model for future high volume satellite plants. Very fragile silicon material produced in both flat ribbon and polygon tubes up to 20 feet long presented an extreme number of pitfalls and formidable challenges.

"Resident experts in the technology" had designed equipment for certain critical process steps that was based on inappropriate technology. Yet they wanted to continue up this blind alley. The time and money wasted nearly closed the doors and pressure from HQ was mounting! We were invited to see if we could find viable solutions.

Solution: We achieved all the objectives by a combination of modifying processes and developing special material handling equipment embodying unique force limiting fixtures and mechanisms for the 20 process steps. Modular construction was incorporated to minimize capital investment. Steps included diamond sawing, diffusion, thermal, chemical, plating, screen-printing, counting, soldering, stacking, inspection, electrical testing, tight process control, assembly, and encapsulation. The systems employed PLC controllers and a commercial robot. The president credited us with saving the company.

PACKAGING DESIGN
(START-UP COMPANY)

Problem: Our Client had contracted to apply handles to special boxes. However, the present method was too material and labor intensive to generate a viable profit. Our Client was behind schedule when we were contacted.

Solution: We changed handle design, cutting part count in half. We changed the attach concept. We designed, built, and installed an innovative semi-automatic machine in six weeks. This reduced material and labor cost 78%.

Our Client was cash-short so we contracted this project on a contingency basis. Our compensation was in the form of a per-box royalty. Patent is pending, covering both handle attaching and machine concepts.

Assembly Operations

Machining Processes

Systems Integration

Automation

Material Handling

Tooling Design

Capital Equipment Design

Mechanisms

PC Board Processing

Casting Processes

Microprocessor Control Systems

Photolithography

Chemical Handling

Packaging Machinery

Plastic Molding

Engineering Organization

Programmable Controllers

Printing and Paper Converting

Food Processing Machinery

Robotics Applications

Screen Printing Equipment

IC Device Assemble, Test, Sort

Sanitary Equipment Codes

Semiconductor Processing

Laser Machinery

Sheet Metal Fabrication