Accessible Test

All Children Have Different Eyes

(Completed―Pass through item)
Technical Research worked with Marketing to have a packaging label to attach to this product when received. The first shipment went into stock in December 2008.

ALL-IN-ONE Board

(Continued)
Following the specifications turn over to Production in September 2008, materials (some ordered in advance due to long lead times) had arrived and were available for production by December. The pilot run of 100 kits was completed in January 2009. At the February de-briefing meeting, several minor issues were discussed. The screws for handle assembly were Phillips head screws. Technical Research noted these screws had been used in the same handle assembly on the mini-light box several years before with poor results. Screw heads had stripped out on handle assembly. Technical Research recommended using Roberts head (square drive) screws for a more positive lock on the driving tool bit to avoid stripping. It was decided to go ahead with the Phillips head screws. Technical Research still felt this would be a problem so, as an insurance policy, Technical Research purchased enough square head drive screws out of the departmental budget ($18.00 worth) to assemble the pilot run. As the pilot run was started, the screws started stripping out. Technical Research retrieved the square head drive screws from the department and gave them to the Production Floor Supervisor. The handle assembly was completed with no further stripping of the screws. The Production Supervisor has since bought enough square head drive screws to complete the remainder of the production run. We also encountered visual (but not tactile) wrinkles in the black Veltex material applied to the board. The Project Leader tried ironing the fabric and this much improved the appearance. It is likely this appearance problem is confined to the last several feet on the roll of material. This would be where the material is most compressed in storage and handling. At the de-briefing, it was decided to make the vendor aware of this problem and ask that they watch for it in future materials production. A second run of 200-250 boards was produced in late February. No problems with the production run of this kit were reported. There have been three reports from customers stating that the handle assemblies were broken upon receipt. Investigation of the returned boards found that the handle arm on one end of the board was broken in all instances it was also noted that the cartons had significant damage. The handle assembly is specified as being manufactured from nylon, which should have stood up to a tremendous amount of impact without breaking. The unbroken arms were flexed and twisted, but did not break. This would indicate the arms were made from the specified material. It was noted that the three units in question were all shipped to northwestern states, which raises a question about how the material might perform under extreme cold conditions. Testing will begin to determine if this may have contributed to the damage. The shipping box may also be a contributing factor. This box is also used for the Azer’s kit and has an auto-lock design at one end of the box. The design was chosen to eliminate some taping during final packaging of the kit. This type of box design depends on 100% fill to assist in putting pressure from the inside. Although the footprint of the box is better suited for the All-in-One, the thickness was determined by the amount of materials with the Azer’s kit. There is not enough material inside to fill the box completely, and though taped, it now has become apparent that end of the box is more susceptible to collapse. The decision has been made to switch to a box with a fold over flap design on both ends of the box, which will provide greater overall strength and integrity to the box. Other methods to improve the packaging, such as foam inserts are also being explored. While the end design of the box was changed from a pop-in-place auto-lock design to a stronger, more traditional tuck-flap, it was ultimately decided that it would be necessary to use an insert to prevent the board from shifting/being damaged. Technical Research worked with the box vendor to develop a corrugated insert that reinforced the existing outer box (which is used for other kits) and locked the All-in-One Board into a central position within the insert by use of strategically placed folding tabs. Technical Research worked with the box vendor through several revisions before a final design was selected. There is a nominal cost for the insert but it will provide greater protection to the board and other miscellaneous components that are packed with it. Following the Project Leader’s approval the insert was added to the bills of materials. The inserts were ordered and successfully incorporated into the next production run of the product. Also worth noting is that the vendor of the dry erase panel has been changed. The original out of state vendor actually subcontracted the boards with a local company. While this company would not deal directly with APH, they had no problem with APH purchasing them from any other established vendor. APH’s Purchasing Department coordinated with an existing APH vendor to become a vendor that handled this product line as well. This vendor and APH have a long history of business together. APH was able to purchase the next order of boards at a significant cost reduction. Technical Research worked closely with Purchasing to ensure that the boards would be manufactured to the same specifications as those originally obtained.

APH Alphabet Card (50-Pack)

(Completed)
Technical Research worked with the Project Leader to facilitate the re-packaging of this product into sets of 50 cards each. Technical Research monitored the progress of this product through placing it into stock in November.

APH Insights Calendar 2010

(Completed)
Technical Research met with all parties to establish a game plan for in-house production of the calendars. Final print files were given to Large Type. Large Type furnished the Tactile Graphics Department proof copies to use in tooling the plates for the calendar. Plates were completed and production began in late spring/early summer of 2009. Technical Research held an update meeting in February and continued monitoring this project through its production and into stock in May 2009. This was a full 3 months earlier than the 2009 Insights calendar which was stocked in August 2008.