Accessible Test

Mini-Lite Box

(Product Maintenance/Redesign)
Component availability forced the overseas factory to source new components for this product. While the vendor was able to locate a new source for most parts, a positive temperature coefficient thermistor that is key to the design still requires a custom production run and can only be purchased in larger quantities. Technical Research has re-designed the light box circuitry to accept a more standard, off-the-shelf component. This should enable the parts to be purchased more easily, less expensively, in lower quantities, and with faster component delivery time. In addition, Technical Research tested and approved a new source for the rechargeable batteries in the unit. The next shipment of the mini-light box is due in November and will use these new components. Technical Research will continue to monitor this product to assure the new circuitry performs correctly.

Picture Maker Bag A Materials

(Product Maintenance)
Technical Research was notified of adhesive “creep” on the foam items in the Bag A parts of the PM Wheatley tactile diagramming kit. The foam materials were shifting after the parts were manufactured resulting in a misalignment between the foam layer of the parts and the polyethylene substrate. Technical Research worked with the Project Leader, Production, and Purchasing to sort all materials that were currently in stock. All defective sets of materials were removed. In checking the history of the parts with the vendor it was learned that these parts had originally been made using a liquid adhesive. This had been switched at some point to a PSA (pressure sensitive adhesive). This was done for ease of assembly and for aesthetics. Future runs of the parts were to be made using the liquid adhesive. The rejected parts were returned to the vendor for re-work. These re-worked parts were received in September but, unfortunately, both the Project Leader and Technical Research rejected the shipment. The re-worked shipment of parts was returned to the vendor a second time. The vendor sent in a bag of parts for testing using a different substrate (flocked styrene). The APH Model Shop subjected the parts to an extended heat test of 125 degrees. The parts did not exhibit adhesive creep. Purchasing contacted the vendor and told them to replace those parts exhibiting adhesive creep with the new, flocked styrene parts. Samples were received in November that met Project Leader specifications. The vendor re-worked existing sets of Bag As and has resumed production of the item. Re-worked Bag As were received and approved in early December. This allowed not only the Wheatley Tactile Diagramming strips kit to be made but also provided materials to make the MathBuilders kits that were back ordered.

Shape Board

(Product Maintenance/Re-Design)
This kit was one of the kits impacted by the fire at the urethane-molding factory. Technical Research re-designed the board used in the kit to avoid the use of the urethane molding process and used a material called ExCel for the board instead. Technical Research completed drawings of the new design of the board after the Project Leader approved the hand-made sample. The drawings were sent out to vendors for bids. Bids were received and the job was awarded. Technical Research reviewed pre-production samples from the vendor. The first samples were rejected due to minor flaws. The second set of samples had the defects corrected and were approved for production. Once the samples were approved, production of the boards by the vendor began in June. Materials arrived at the APH dock in late June and production of the kits was started in July. Kits with the new Excel based board were placed in stock in late July. The board used in this run was green in order to use the existing materials currently in stock. By avoiding scrapping the current shapes in stock a savings of over $6,500 was realized. Also, since the mold was not needed, $1,200 in tooling costs was avoided. Yet another savings was in the cost of the board itself. The urethane board cost $16.00. The new ExCell board costs $10.75. This is a per kit savings of $5.25 and an estimated annual savings of $1,443.75 based on annual kit production of 275 units. With the existing materials for the shapes used up, a new color board will be incorporated into the kit and all shapes will be re-designed from a standpoint of size and color. Savings on this project will be turned in to the 2009 company continuous improvement program. Technical Research worked with this product on its initial production run and will continue to work on the re-design of this kit incorporating different colors for the pieces and the board as well as improving the shapes used in the kit.

Sound Balls (Techno beat and Boing Boing)

(Product Maintenance)
Due to production problems at the Taiwan production plant, the sound ball production was moved to China. This took a great deal of time and effort on both the part of the overseas representative and APH Technical Research. Following initial samples made by the China facility, all tooling was moved from the Taiwan plant to the China plant. Pre-production samples were made and sent to APH. These were tested and problems noted. Several sets of samples were sent back and forth between China and APH. The problems with the samples were solved and production began in early 2009. Production was completed and the balls shipped via ocean freighter and rail to U.S. customs. The balls arrived at APH and were inspected by both the APH quality assurance and Technical Research departments. These balls sold very quickly due to pent up demand. A second production run was started on the balls in July and completed in late August. These were shipped via ocean freighter and rail to U.S. customs. They are expected to clear customs and arrive at APH in late September to early October. Technical Research will follow up on this shipment to assure the balls were produced correctly. Technical Research continues to work on this item with the Purchasing Department and the sales representative.