“Winning the day.” It’s an inspirational and aspirational challenge to the entire Kaysun team that encourages finding and making daily improvements to help everyone meet their daily goals.
But changes for the better aren’t effective if they exist in a vacuum. Just as continuous improvement requires every team member to act as empowered individuals, its success relies upon cross-functional teams to effectively solve problems.
As the future expands for Kaysun Corporation, so does the facility. July 2022 marks what CEO Ben Harrison calls “an exciting milestone.” The company is breaking ground to add 65,000 square feet of combined office and manufacturing space to its existing facility over the course of about 8 months.
There’s no such thing as a typical day at Kaysun. Then again, Kaysun isn’t your typical custom injection molder.
Generally speaking, Design for Manufacturability (DfM) is the process of consciously and proactively designing products to optimize all facets of manufacturing.
DfM methodology aligns engineering and production in the design phase, ensuring cost and time efficiencies, superior quality, regulatory compliance, and end-user satisfaction.
Central to maximizing these DfM benefits is prioritizing Failure Mode Effect Analysis (FMEA) within the larger plastic part analysis to assess risk probability. Identifying and addressing problems early in the product development process prevents costly issues that could impact manufacturability such as plastics selection, tight tolerances, and secondary operations.
Up until World War II, achieving necessary product functionality at the lowest cost was usually done by any means necessary. However, the war-related scarcity of materials and parts compelled General Electric engineers to find material substitutes.
Many of the substitutes reduced project costs and improved overall product performance — and the standard practice of finding cost-effective manufacturing solutions without compromising product functionality or quality was born. Today, we know it as "value analysis" for existing parts or “value engineering" for new parts.
OEMs across many industries can attest to the benefits of plastic injection molding. It’s ideal for consistent, affordable production of a wide range of high-quality complex plastic parts that can withstand about any environment.
That’s reason enough to rank injection molding high on the list of go-to solutions, but there’s more. To better understand how and why manufacturers use the process, let’s take a look at the individual merits of the top 14 benefits of plastic injection molding (listed in no particular order):
Globally, the annual injection-molded plastics market is currently valued at approximately $260 billion, with a projected 5% CAGR over the next five years.1
These substantial numbers validate the continued and increasing reliance on injection-molded solutions for a variety of applications across industries. They also indicate how much the role of a custom injection molder has changed, shifting from general supplier to trusted partner.
Manufacturing processes can be susceptible to inefficiencies. Continuous improvement practices counteract these shortcomings by proactively identifying and eliminating them, thereby improving process and part quality. In turn, quality parts perform better, longer which is a win-win for the injection molder and OEM.
OEMs regularly face an important decision: use a supplier from overseas or partner with a US-based supplier.
Why is this so important? Because if your supplier is somehow incapacitated and deliverables are delayed, your orders go partially or wholly unfulfilled. That has a negative ripple effect on your customers and your reputation. This is evident from Thomas' March Industrial Survey, which saw a reduced desire from US manufacturers to source internationally (43% in February to 34% in March), and increase in those looking to source from North American manufacturers (47% from 43%).