Kaysun Blog

Oil and gas are natural resources harvested from beneath the earth’s surface. Sophisticated production, gathering, processing, transmission, and distribution systems can expose industry workers to the risk of natural gas poisoning — even in the oil business, as some underground crude contains natural gas.

The poisoning causes varying degrees of illness, from fatigue and headaches to the potential for suffocation if left untreated. Natural gas & oil industry OEMs understandably take the threat seriously and routinely issue personal protective equipment (PPE) to keep workers safe.

The power grid in the United States is shorting out. What began in the 1880s with some isolated power generation systems is now straining to support an estimated 7,300 power plants, and millions of miles of high- and low-voltage power lines in order to service about 200 million customer sites nationwide.¹

The increasing number of rolling blackouts, prolonged outages related to natural disasters, and the looming risk of cyberattacks all point to the need for an electricity infrastructure overhaul. It’s an issue of ongoing debate in the political arena. In the meantime, energy distribution sector OEMs are actively seeking solutions to stem the impact of the current flagging power grid.

Many manufacturers are turning to their suppliers for guidance and innovation as much as for parts and products. Solutions for the energy distribution market must be versatile and reliable, which aligns with the benefits of injection molding.

With a facility expansion now complete, Kaysun Corporation is more prepared than ever to serve its customers while creating job opportunities in the Manitowoc area.

The 1,250 landfills in the United States are projected to reach maximum capacity within the next few decades. Pair that with the fact that, globally, 91% of plastic waste isn’t recycled, and the devastation of the eco-crisis becomes shockingly real.

Protecting the planet is everyone’s responsibility, including — and perhaps especially — corporations routinely using eco-sensitive materials. As a custom injection molder, Kaysun handles thousands of tons of plastics annually which are processed into injection-molded parts.

Consumer goods manufacturing is increasingly dependent on automation. Robotics currently complete 52% of production line tasks within the consumer goods and pharma industries.¹ The percentage is second only to the combined 70% used across the automotive (38%), electronics (15%), plastics and chemicals (10%) and metals (7%) industries.²

“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 55,000 square feet of 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.

Identifying and addressing problems early in the injection molded product development process prevents costly issues that could impact manufacturability: plastics selection, tight tolerances, and secondary operations. Fortunately, two  methodologies — DfM and FMEA — help manage injection molding risk.

First, we need to explore the meaning of DfM. Design for Manufacturability (DfM) is the process of consciously and proactively designing products to optimize all facets of manufacturing.  It aligns engineering and production in the design phase, ensuring cost and time efficiencies, superior quality, regulatory compliance, and end-user satisfaction.

Maximizing DfM's benefits depends on prioritizing Failure Mode Effect Analysis (FMEA) within the larger plastic part analysis to assess risk probability. FMEA is but one example of the technical expertise required to successfully execute DfM for complex applications. It also underscores the importance of partnering with an injection molder experienced in DfM to reap the following benefits.