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Engineering Case Studies
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- Issue: Screw recovery – inefficient setting caused excessive component wear
- Expectations: improve cycle time AND eliminate premature component wear
- What we did: upsized 100mm screw to 125mm
- Results: cut cycle time by 1/3 while enabling recovery at a lower RPM
- ROI: $150,000 annual savings – $50/hour machine bill rate; three-shift operation
- Issue: Defects – several PC jobs
- Expectations: reduce or eliminate defect occurrence
- What we did: implemented custom screw design to correctly process PC resin
- Results: 20% reduction in scrap rate and 25% increase in output
- ROI: $250,000 annual savings – $250/hour machine bill rate; two-shift operation
- Issue: Loss of cycle time and inconsistent feeding – premature screw wear
- Expectations: eliminate recovery anomalies to increase throughput
- What we did: custom formulation to withstand corrosion; improved feeding on 25mm screw
- Results: 20% reduction in scrap rate and 25% increase in output
- ROI: $60,000 annual savings – $50/hour machine bill rate; three-shift operation
- Issue: Excessive splay – PC blend job; rework required an additional operator
- Expectations: eliminate extra operator through reduced defects
- What we did: implemented low inventory screw design [downsizing not appropriate]
- Results: reduced residence time which eliminated defects and the need for extra operator
- ROI: $80,000 annual savings – burdened labor cost
- Issue: Unwanted black specks – color ABS part
- Expectations: eliminate or significantly reduce defect due to black specks
- What we did: downsized 115mm screw to 80mm; residence time reduced from 11 to 4 minutes
- Results: speck issue eliminated; scrap rate reduced by 10%
- ROI: $35,200 annual savings – $80/hour machine bill rate; two-shift operation