Entrepreneur had a successful product; the current manufacturing process limited the units that could be produced to 30,000 per year. The challenge; he had order for four times that quantity and a marketing plan to further grow sales.
Solution:
Franchino Mold & Engineering analyzed the existing product. First we re-designed the product to a modular concept for ease of installation. Secondly we change the design to allow the parts to stack efficiently reducing the area required when shipping. Most importantly we changed the manufacturing process to a more efficient structural foam molding. Franchino Mold designed and manufactured the structural foam mold and introduced the entrepreneur to one of our molding partners.
Results:
The entrepreneur can produce up to 500,000 units per year.
The mold cost was paid back in less than six months.
The structural foam process reduced the cycle time and decreased the piece price by 64%
The revised stacking design reduced freight costs by 35%.
The quality and consistency of the product improved dramatically.
The entrepreneur grew his business and recently landed a contract with a fortune five hundred company.
