DeKALB Champions Seat Support Pallet

“I would recommend working with DeKALB because of their ability to plan very well and not let any issues fall through the cracks.” Mitch Kujawa, Polyflex

The Challenge

Polyflex was in the market for a structural plastics company to produce the bases for a seat support pallet, as they did not have a large enough press to run the project. The seat support pallet was being produced for the end manufacturer, Magna, who supplies for Chrysler. The final purpose of the seat support pallet was for seat material handling, so that seats can be brought through the assembly line.

DeKALB was chosen due to their ability to design ribs and manage overall mold ability of the part. The project required four towers, which the team worked to fill properly with correct nozzle configurations. Attachment points and interfaces with the steal components were analyzed by the team to ensure proper functionality as they went from steal to plastic pallet.

DeKALB’s Solution

DeKALB partnered with a tool source to ensure the tool was molded properly and according to quality standards. Advanced Quality Planning (APQP) was utilized in the designing and tooling phases to ensure a successful outcome. Additionally, regular meetings with the tool source were managed by the DeKALB team to make sure Polyflex/Magna was comfortable with the process and all timelines were met.

Communicative Approach

The team at DeKALB started the project with a strong program management approach. They made certain to communicate any potential design concerns upfront; with a solution plan already in place. This strategy included all initial design meetings.

Once in the tool quoting phase, regular meetings were scheduled with Polyflex and DeKALB to identify any concerns and report progress. Polyflex was very communicative and comfortable with this process as the DeKALB team planned structured agendas in order to identify issues as well as provide solutions to solve them.

In addition to weekly meetings, team members were easy to reach by phone and email. They responded quickly with answers to any questions or concerns. Overall, the DeKALB team was very proactive and did a great job of displaying how any change would affect the overall timeline.

Successful Result

Everyone at DeKALB was very committed to the success of this project and the mold trial was realized without a hitch. Polyflex managed the buildup at their facility and then sent to Magna to complete the final review.

In the end, all parties were very pleased when the first run of the tool was realized and approved as qualified by a tool expert and production is set to begin in May 2014. Polyflex could not be more satisfied with the project management displayed by DeKALB and would recommend the team based on the positive outcome of the seal support pallet.

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