salesoffice, Author at AFAC Masking Systems

Posted on 11th June 202429th July 2024 by salesoffice

Case Study: Innovative Masking Plug for Enhanced Production Efficiency

Welcome to AFAC Custom Masking Division! Today, we are excited to showcase an innovative plug designed to solve a specific masking challenge faced by one of our customers. This case study highlights how our tailored solution improved their production efficiency, precision, and cost-effectiveness.

The Challenge

The client, a manufacturer struggling with centering self-adhesive dots around holes during production, needed a more reliable and efficient masking solution. The primary issues were difficulty in achieving precise placement and the inefficiency of using self-adhesive dots, which often led to production delays and increased costs.

Our Solution

To address these challenges, AFAC designed a custom plug with the following key features:

Comprehensive Masking: The plug effectively masks not only the hole but also the surrounding area, providing a more thorough solution than self-adhesive dots.
Hollowed Back Design: The plug features a hollowed back, which reduces the amount of silicone used in its production, thereby cutting costs while maintaining functionality.
Small Handle for Easy Removal: A small handle is incorporated into the design, ensuring that the plug can be easily inserted and removed, streamlining the masking process.

Implementation and Results

The custom plug was integrated into the client’s production line, leading to significant improvements:

Enhanced Efficiency: The easy-to-use design allowed for quick and accurate placement, reducing production time and increasing throughput.
Increased Precision: By masking both the hole and the surrounding area, the plug ensured precise coverage, improving the quality of the final product.
Cost-Effectiveness: The hollowed back design reduced material costs, and the reusable nature of the plug further contributed to long-term savings.

Client Feedback

The client was extremely satisfied with the custom masking plug. They noted the substantial improvement in production efficiency and precision, as well as the cost savings achieved through reduced material usage and increased reusability. The ease of removal and placement was particularly praised for simplifying their workflow.

Conclusion

This case study exemplifies AFAC’s commitment to developing innovative and cost-effective solutions tailored to our clients’ specific needs. By addressing the challenges faced by the manufacturer, our custom plug enhanced their production processes and overall product quality.

If you are a quality manager, production manager, or product designer seeking custom masking solutions to optimise your manufacturing processes, AFAC is here to help. Contact us today to discuss your requirements and discover how our bespoke products can enhance your operations.

Get in Touch

For more information on our full range of capabilities, please complete the form below or contact our team directly on 0345 094 0993. At AFAC, we’re committed to pushing the boundaries of what’s possible with silicone rubber mouldings.

Posted on 11th June 202429th July 2024 by salesoffice

Case Study: Custom Pull Plug for European Wheel Manufacturer

Welcome to another case study with AFAC Custom Masking Solutions. Today, we are excited to highlight a specially developed pull plug designed for a European wheel manufacturer. This case study focuses on the application and benefits of this custom solution in the manufacturing of wheels for large vehicles.

The Challenge

The client, a prominent European manufacturer of alloy and steel wheels for large vehicles, faced a critical challenge in their powder-coating process. Ensuring a powder-free chamfer on the wheels was essential for safety, as it allowed for accurate metal-to-metal contact when bolts were torqued. Any powder build-up on the chamfer could lead to powder cracking, resulting in inaccurate torque settings and potential wheel failure, posing significant safety risks.

Our Solution

To address this issue, AFAC developed a custom pull plug specifically designed to protect the chamfer on alloy and steel wheels during the powder-coating process. Here are the key features of our solution:

Effective Protection: The pull plug provides robust protection for the chamfer, preventing any powder build-up during the coating process.
Ease of Use: Designed for easy installation and removal, the pull plug ensures a seamless fit, which enhances efficiency on the production line.
Durability: Made from high-quality materials, the pull plug is durable and withstands the rigorous conditions of the manufacturing environment, ensuring long-term usability.

Implementation and Results

The custom pull plug was successfully integrated into the client’s manufacturing process, yielding significant improvements in safety and efficiency. Here’s how it impacted their operations:

Safety Enhancement: By preventing powder build-up on the chamfer, the pull plug ensured accurate metal-to-metal contact, eliminating the risk of powder cracking and potential wheel failure.
Reliability: The precise protection provided by the pull plug contributed to more reliable torque settings, enhancing the overall safety of the wheels.
Efficiency: The easy-to-use design of the pull plug streamlined the production process, reducing downtime and increasing throughput.

Client Feedback

The client was highly satisfied with the custom pull plug solution provided by AFAC. They appreciated the significant improvement in the safety and reliability of their wheels. The efficiency gains in their production process were also noted as a major benefit, as it allowed for smoother operations and reduced potential for error.

Conclusion

This case study showcases AFAC’s commitment to developing custom solutions that address specific challenges in manufacturing processes. By designing a pull plug that effectively protects the chamfer on wheels, we were able to enhance both safety and reliability for our client in the heavy machinery sector.

If you are a quality manager, production manager, or product designer looking for custom masking solutions to improve your manufacturing processes, AFAC is here to help. Contact us today to discuss your requirements and discover how our innovative solutions can support your production goals.

Get in Touch

Posted on 11th June 202429th July 2024 by salesoffice

Case Study: Self-Adhesive Masking Solutions for Waterproof Instrument Bodies

Welcome to AFAC Custom Masking Division! Today, we are highlighting a successful application of our self-adhesive masking solutions for a customer who designs and manufactures waterproof instrument bodies. This case study showcases how our self-adhesive masks and complementary plugs have streamlined their production process, providing flexibility and efficiency.

The Challenge

Our customer needed a reliable masking solution to ensure that specific areas of their waterproof instrument bodies remained clear during the powder coating process. This requirement was crucial to maintain the integrity and functionality of the instruments. Additionally, they sought a solution that offered flexibility to accommodate design changes and new trials without relying on external suppliers.

Our Solution

AFAC provided a comprehensive self-adhesive masking solution tailored to the customer’s needs:

Red Self-Adhesive Masks: These masks are designed to withstand the powder coating process while ensuring precise coverage of the designated areas. The high-quality adhesive ensures they stay in place, preventing any coating from reaching the masked sections.
Complementary Plugs: Plugs are used at both ends of the instrument bodies, providing complete protection and ensuring no powder infiltration during the coating process.
Self-Adhesive Material on Rolls: The customer opted to purchase self-adhesive material on rolls, allowing them to cut shapes internally. This approach provides significant flexibility, enabling them to adapt quickly to design changes and conduct new trials without waiting for externally sourced materials.

Implementation and Results

The implementation of AFAC’s self-adhesive masking solution led to several positive outcomes for the customer:

Streamlined Production Process: The use of red self-adhesive masks and complementary plugs simplified the masking process, reducing preparation time and increasing overall efficiency.
Flexibility and Adaptability: By cutting their own shapes from self-adhesive material rolls, the customer could easily accommodate design modifications and experimental trials. This flexibility reduced downtime and accelerated the development cycle.
Enhanced Product Quality: The precise masking ensured that critical areas remained clear during powder coating, maintaining the waterproof integrity and high quality of the instrument bodies.

Client Feedback

The customer expressed great satisfaction with the self-adhesive masking solution provided by AFAC. They highlighted the significant improvements in their production workflow and the enhanced ability to adapt to design changes swiftly. The reliability of the masks and plugs during the powder coating process was particularly appreciated, as it ensured consistent product quality.

Conclusion

This case study demonstrates AFAC’s commitment to delivering innovative and flexible masking solutions tailored to meet specific customer needs. By providing high-quality self-adhesive masks and complementary plugs, we helped our client streamline their production process and maintain the high standards required for waterproof instrument bodies.

If you are a quality manager, production manager, or product designer seeking adaptable and efficient masking solutions for your manufacturing processes, AFAC is here to assist. Contact us today to discuss your requirements and discover how our tailored products can enhance your operations.