Accessible Test

Azer’s Interactive Tactile Periodic Table Study Set

(Product Maintenance)
The pilot and production runs of this product were very difficult. Many problems were encountered by the vendor when attempting to fabricate the atomic model board. Technical Research designed a fixture for manual application of the Veltex to the atomic model board as a stop-gap measure to enable the production run to be completed in-house and on time. These difficulties were discussed in the de-briefing meeting on this product after the first production run. The Model Shop and Project Leader worked with the outside vendor originally making these boards to work out a solution. Experiments were conducted using a different substrate (styrene vs. ExCell) by the Model Shop. The Model Shop worked with an outside vendor to cut test pieces using the new materials chosen for the board. The experiments were successful. Product structure in SYSPRO was modified to reflect the new materials. A successful production run was made using the new substrate and different adhesive backing on the Veltex.

Chang Kit

(Product Maintenance)
This kit was one of the kits impacted by the fire at the urethane-molding factory. The kit has a pair of urethane molded gingerbread men in it. Technical Research worked to create a new cutting file for the CNC router to make the gingerbread men out of ExCell material. Technical Research intentionally used existing materials in existing sizes, which enabled the use of existing clamping fixtures for the plastic while it was being cut. Technical Research submitted samples to the Project Leader who approved them. One hundred and fifty-four gingerbread men (77 kits’ worth) were cut in December and were sent to the Educational Aids Production Supervisor’s office. This quantity was used to fill back orders on this item. Technical Research also learned the purchased gingerbread men cost $3.50 apiece or $7.00 per kit. The new, cut out gingerbread men cost $0.35 each or $0.70 per kit. This is a cost saving of $6.30 per kit. At anticipated 126 kit sales per year, this works out to an annual saving of $793.80. An additional $1,200.00 savings for APH was realized by avoiding re-making the mold. This kit was slated for a re-design that would make any molds made obsolete. Technical Research’s work on this project resulted in a total saving of $1,993.80 for the year. This is project is being submitted to the company’s C.I. efforts. A key material (Veltex for the Chang board) arrived in early April. Production on the kit started April 21. Technical Research monitored this product through completion of its production run. Kits were placed into stock in April.

Consumer Product Safety Improvement Act (CPSIA)

In reaction to the fall and winter 2007 news accounts of children’s jewelry being imported from China that had been made from lead and major toy manufacturers (Mattel being one) having problems with lead contaminated paint on their products, the U.S. Congress passed the consumer product safety improvement act in the latter part of 2008. This new law sets tighter standards for the allowable levels of lead in products (current 600ppm (parts per million) to 300ppm and ultimately 100ppm), sets limits for phthalates in plastics, and makes safety testing based on ASTM F-963 mandatory (American Society of Toy Manufacturers). F-963 was a voluntary standard that APH had complied with prior to the new law. APH testing of new products for F-963 compliance was always performed in-house prior to releasing a new product to production. In addition to the stricter standards the new law also mandates 3^rd party testing of production runs of product for compliance by an independent, accredited lab and requires tagging of product “where practicable” in order to be able to trace the production origins (production dates, lots, etc) of any given production run. Technical Research has worked with the executive committee to make the company aware of the potential impacts the new law will have on APH company operations. In addition, Technical Research worked with the Purchasing Manager and the Materials Planning Manager to draft a letter to our vendors informing them of the new law and its requirements. Technical Research also participated in drafting a statement sent out to Ex-Officio trustees as well as a statement that now appears on all APH catalogues noting that the products are for educational purposes and should only be used in a supervised and structured environment. Technical Research spent time during the winter and spring of this year investigating the new law and industry reactions to comply with the law via the internet and other sources. This past spring Technical Research participated in a webinar given by SGIA (screen graphics images association) covering the new law and its impact. Technical Research made notes during the webinar and distributed them to members of the Executive Committee and others the next day. The new law is in a state of almost continuous flux. Many manufacturers are petitioning Congress for amendments to the law to enable manufacturers to comply with the law in the most efficient, least burdensome manners possible. Congress has passed a stay of enforcement of the testing and certification portions of the law but all products produced after Feb 10, 2008 must comply with the standards set forth in the law. Technical Research will continue to monitor the law’s progress and work with internal company personnel to keep them informed and to support them in whatever capacity is needed.

Department of Education Presentation

(Special Project)
Technical Research participated in a 4-person presentation to the DOE on March 9 giving examples of how APH is monitoring new and emerging technologies for use in APH products. The team was originally Jack Decker, Steve Paris, and Frank Hayden. Frank Hayden recommended Anita Rutledge be part of the presentation due to her work specifically on rapid prototyping. The entire presentation was well received by the DOE but Ms. Rutledge’s portion was particularly well received as was the hands-on demonstration of the RPM software that was set up on the plant tour for the DOE representatives.