Services

Problem:

Existing adhesives required fixturing and long cure times, messy application process

Approach:

Developed self-fixturing, triggered-curing, die-cuttable film adhesive

Measurable Outcomes:

$110 M opportunity, customer initiated validation testing, 10 granted patents

Problem:

Existing products had unacceptable performance with aluminum intensive designs

Approach:

Improve adhesion and enhance stress-durability through formulation design

Measurable Outcomes:

$10 M opportunity, customer initiated validation testing, 1 patent application

Problem:

Existing finishes had unacceptable toxicity profiles

Approach:

Developed non-toxic finishes compliant with EPA-minimum risk pesticide requirements

Measurable Outcomes:

$1.4 M opportunity, customer initiated validation trial

Problem:

Customer requirements were not collected in the field, lead times on samples were 4+ weeks

Approach:

Automated requirements collection, categorized sample type by feasibility, systematized scheduling and documentation

Measurable Outcomes:

Reduced fulfillment lead times by 75%, achieved 95% user adoption rate, 90% product documentation rate

Problem:

Early stage startup needed to engage analytical labs capable of performing analysis to support process development and commercialization

Approach:

Engaged 8 candidate labs to determine capabilities, capacity, and cost

Measurable Outcomes:

Identified 2+ candidate labs for each technique and full qualification testing, facilitated handoff to client for ongoing analysis

Problem:

New part design called for unique bonding process to achieve part quality and build rates, no existing specification or approved material on record

Approach:

Evaluated candidates from 6 global suppliers, used screening tests to downselect options for full qualification, collaborated with engineering to define specification

Measurable Outcomes:

Supported launch of $900 M product line

Problem:

Intermittent sealer application defects, from variable material supplier quality, led to 3% defect rate and additional operator time to adjust sealant application process and rework defects

Approach:

Engaged incumbent supplier to improve quality and 2 new suppliers for a second source, qualified new source according to company standards and validated quality of initial builds

Measurable Outcomes:

Eliminated rework and increased plant output by $250k finished product per day

Problem:

Bonding process defects could escape detection because procedures were inadequate or too cumbersome for routine use

Approach:

Defined methods for evaluating bond quality with common tools, built tool for recording and displaying dashboard of results

Measurable Outcomes:

Reduced warranty risk pool by 90%

Problem:

Windshield moldings on the top 2 product models had 75% failure rate during final vehicle quality checks, large quarantine pool, rework delayed delivery of finished product

Approach:

Developed audit test to identify and quarantine defective parts before installation, collaborated with engineering, quality, and suppliers to trace root cause to molding equipment failure

Measurable Outcomes:

Resolved quality issue affecting $40 M of product

Problem:

Lack of materials standard resulted in confusing change management and validation procedures, quality risks

Approach:

Identified 4 use cases for foam tapes across 6 product lines and 3 factories, defined specifications and test methods for each case collaboratively with engineering

Measurable Outcomes:

Standardized tape products used in vehicles generating $8 B revenue