SSL Corn / Callous &
Smoothing File

McKechnie Plastic Components, Stamford Bridge were nominated by healthcare company SSL Ltd to be the sole manufacturer of a new range of foot-files.

Alongside a product re-vamp, including a new twin shot soft grip handle, a number of improvements were necessary to overcome some of the shortcomings of existing products. These improvement criteria needed to be sustainable for the high production volumes required and be ready for launch.

To meet the above, a 2-stage plan was adopted:

Prototype Tooling Programme

The decision to nominate Design 4 Plastics and Mold Systems Tooling Ltd on the prototype-tooling programme became justified, when within 28 days of order the first tools were sampled, a week ahead of the initial target. This enabled us to bring forward the testing programme for materials, allowing additional time for tool / design development.

Production Tooling / Automation Cells

Running concurrently with the prototype tool programme was the commissioning of multi-impression production tools and two sets of automated sub and final assembly cells. Our chosen partners were Ever Ready Tools Ltd and Hi-Tech Automation Ltd with a combined Capital expenditure budget of circa £700k. The development of these systems was closely controlled through weekly project review meetings.

Project Achievements:

Innovation

• Creation of a capable rasp encapsulation system, the scope of which included developing a highly automated progression metal pressing production tool
• Development of an abrasive system that bonds directly to a 3D plastic substrate and performs as the traditional ‘Carborundum system’ yet does not detach once wet.

Production Costs / Production Efficiency

• Multi-cavity family moulds allowing matched sets to be manufactured in economic volumes.
• High-speed insert loading and product de-moulding robotics.
• Intelligent 6-axis assembly robotics.
• Intelligent ultrasonic assembly units.
• The incorporation of bespoke returnable insert handling trays that directly feed into the production cells.

This approach reduced direct labour content, increased efficiency and generated a stable production process.

Improved Product Quality

Considering the issues with the current product, the new design addressed the failure modes of:

• Rasps becoming detached.
• Handles breaking in ‘normal use’.
• Carborundum pads from detachment when wet.

Use of Technology to Increase Profit

The new range of products also added value by:

• Improving handling ergonomics.
• Giving grip through the introduction of TPE overmould upon a rigid PS substrate.
• Created an up market image through the product style with a family platform providing a customisable product for sales differentiation.
• Reduced by design risks of litigation and warranty claims.

The new range of foot-files were successfully launched on time, to cost and within the original capital expenditure budget. A prime example of how a professional collaboration with UK toolmakers, automation and material suppliers alongside a truly proactive and supportive customer can bring real benefits to all in terms of cost, quality and delivery.