Case Study: When You Save A Customer Money With an Idea They Had Not Considered

At Plastics Unlimited, we thrive on thinking outside the box to deliver creative, innovative solutions that address our customers’ unique needs. One great example of this ingenuity lies in how we approached mounting brackets for certain parts—an area where we found opportunities to improve efficiency, reduce costs, and streamline production for a leading manufacturer of agriculture equipment.

Traditionally, metal mounting brackets are created and attached separately, adding extra steps to the manufacturing process, driving up costs, and creating potential inefficiencies. But rather than settling for the standard approach, we asked a simple question: “What if we could do more with what we already have?”

Our solution was both clever and effective. We began molding mounting brackets directly into areas of the part that would otherwise go unused or wasted. This strategic design not only makes full use of every available inch but also improves the overall functionality of the product. Once molded, the brackets are precisely glued to the back side of the parts, eliminating the need for separate manufacturing runs or hardware pieces.

The benefits of this approach quickly became clear:

• Lower Costs: By incorporating brackets directly into the design, we eliminated unnecessary steps, saving on time, labor, and material waste.
• Increased Precision: Molding the brackets ensures they are consistent and accurate, improving the parts fit and performance.
• Supply Chain Improvements: This method reduces reliance on additional components or third-party suppliers, helping us mitigate supply chain issues and maintain production timelines.

This creative solution is a perfect example of how we leverage smart design, innovative manufacturing techniques, and years of expertise to deliver better results for our customers. By thinking differently and finding opportunities to optimize, we provide parts that are not only cost-effective but also smarter, more reliable, and ready to meet the challenges of our customers.

At Plastics Unlimited, we believe that sometimes the best ideas come from simply looking at a problem from a new perspective—and finding value where others might only see waste.

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