While manufacturing a double colour
product, once a reaction was finished, one layer manifested inclusions of a
different colour and colour changes, thus rendering the final product
unavailable for sale due to incorrect appearance.
The production process as well as raw
materials, equipment and technologies being used were all analysed. We
determined the source of such problem, being one of the compounds used in the
other layer. It affected thermal dynamics of the reaction between the two
product layers. We introduced a time interval between introductions of the
layers in the mould, thus removing the problem.
The off spec product ratio, being a waste product, was reduced
The company generated savings (waste reduction) and increased production efficiency (no need to make larger product batches);