| Total
Cost Savings Overview: Two-Part RTV and Hot Melt Sealants |
| Cost Savings | 1-part | 2-part | Hot melt |
Handling
Savings | Parts must cure
for 24 hours | Parts can be
handled after 10-20 minutes | Parts can be moved
between processing steps without delays |
Labor
Savings | Two operators are
often needed to move parts | Parts can be moved
via conveyer belt (no operators needed) | Parts can be moved
via conveyer belt (no operators needed) |
Storage
Savings | 150 to 200m2
required floor space for part storage | No storage space
needed | No storage space
needed |
Waste
Reduction | Manual application
leaves excess material that requires tooling | Robotic
application equipment reduces material needs up to 40% | Robotic dispensing
equipment reduces material needs up to 40% |
Climate
Control
Savings | Optimal cure time requires
climate/humidity control | Cure time independent of
humidity | Develops high green strength
(=instant bonding) but continues to cure as a 1-part |
Quality
Savings | Improper handling of incompletely cured
parts can damage the bond line | Fast cure time significantly reduces
risk of part damage due to handling | Fast cure time significantly reduces
risk of part damage due to handling |
Total
Cost
Savings | --- | Up to
25% | Up to
25% |
| The Dow Corning
Advantage: Manufacturer Transforms Production and Lowers Costs |
|
Challenge
A leading
household appliance manufacturer came to Dow Corning for help with increasing
their production. Our engineers worked with the customer to analyze each aspect
of their production process, soon discovering one-part RTV was being used to
bond the inner oven door to the metal frame. The Dow Corning team concluded
that the total amount of sealant used in production could be dramatically
reduced by moving to a two-part RTV solution.
|  |
Solution
Dow Corning then developed a total cost model that covered each step of the
production process, highlighting the reduction in material and labor costs as
well as handling time. |
|
Results
Final results show that even with a higher unit cost for the two-part sealant,
our customer would see reduced total production costs with no impact on
efficiency or product quality. Notable numbers include:
-
14% reduction in material
cost
-
58% reduction in total dispensed
sealant
-
85% reduction in machine
downtime
More importantly, Dow Corning
sealant solutions technology and expert advice allowed the
manufacturer to increase next year's production goals by over 25% while still
controlling costs
and producing a superior product.
|