First project: Popcorn Bucket/Black Panther Light

Client: PKN Company

Main products: Black Panther light series products

First project: Popcorn Bucket/Black Panther Light

Development duration: N days

Development process and description:

1. First, Follow up making a pony popcorn bucket, the development of the mold with a long time, repeated repair mold to confirm the goods, do goods during the product has poor pad printing, cracks, shrinkage and other problems.  Later customers feedback our development time is too long, repair mold time is too long, we did not cooperate with the popcorn bucket.

2. We started to cooperate with the Black Panther lamp, and the early development and mold opening of the hand plate went smoothly.  We started to do the pre-production sample, but there were some problems like runic marks and black bubbles in the transparent part of the vinyl Panther lamp head, and the customer refused to accept the sample and asked for improvement.  Because of the limitation of the vinyl process, the PVC pulp flows unevenly in the mold and leaves a flow line.  The vinyl factory modified and made several products with good effect and sent them to the customer for confirmation of mass production, and the customer confirmed mass production.  During the mass shipment, the factory did not inspect the fine lines too much, and there was no problem in checking the surface of the vinyl.  In addition, due to the irregularity of the black panther lamp head and the deformation of the vinyl glue, the oil injection mold was completely useless, and the oil injection position was not in line.  The first way I thought of was to stick stickers to cover the light transmission position and spray color, the spray effect was not good, flying oil, the solid color part of the light transmission, the light position sprayed into the color, and the cleaning time took a long time;  To the assembly, the adhesive glue of the black panther lamp head and the ABS base overflow, the glue parts are white, the gap, the glue is not hard, and so on, the customer continues to ask the goods to rush out 300 goods overnight before the New Year.

3. After receiving the goods, the customer found a series of problems: flow marks, black spots, bubbles, glue overflow, white, dense finger marks inside the base, rubber parts falling off, light transmission of the solid color part, flying oil, poor function of the light, serious scratching at the bottom of the base...  And so on.  According to the customer's feedback, the whole batch of goods are basically not ok.  Among them, the flow pattern and dense finger marks in the base are unacceptable, and the flying oil and adhesion are most unacceptable.  We sent another kind of special glue to the customer, The customer gave feedback that all 300 goods were disassembled and reworked.

4. After that, it is a long road of rectification to rectify the flow pattern.  In the early stage, the effect can be very good because several samples are made.  Every once in a while, I urged the supplier to provide confirmation of the rectification, and the supplier gave feedback to debug other material tests.  The time was delayed again and again, and I repeatedly urged the supplier to update the photos and videos to the customers.  However, the flow marks are really unavoidable.  The supplier finally makes the plastic parts out, selects the good ones, and then uses tools to smooth the flow marks on the transparent parts inside the vinyl glue for delivery.  After receiving the goods, our QC will check the qualified ones with lights one by one and provide several batches (about 30,50,100 pieces).  The supplier's feedback was that the output was too low, the time was too long, and the cost was too low.  The supplier stopped production again, debugging, pushing, debugging, and finally chose to use the oil furnace.  The inside of the product was smooth, the black spot bubbles were also improved, but there was a small part of the flow line and an obvious exhaust hole below.

The factory uses the method of making stickers, making the light-transmitting position into a sticker to cover the oil spray, and the position of the silver thin strip is painted by hand.  But this way still can not avoid the cost, later through the lighting one by one cleaning repair, QC one by one inspection, defective products return to rework;

As for the problem of bonding, the factory uses a specific glue, which has a limitation, the bonding time is long and it takes at least half an hour to dry, and the assembly time is long.

The scratch problem of the base can be improved by modifying the mold later and raising the edge of the base, but it cannot be completely avoided

As for the problem of poor fingerprint function, be careful during the production process and re-enter the box after each inspection

In SUMMARY:

● For products with sufficient experience, the development time can be shortened as far as possible under the premise of ensuring quality

● For products that are not familiar with or understood, inform the existing problems in advance, such as vinyl lamp making, process limitations, and the appearance of internal flow lines. The larger the product is, the more obvious it will be, inform the customer in advance before development, so as to avoid feedback from the customer later on, the copyright requirements of the product are strict, the rectification time is long, the cost is high, and the customer will be lost if it is serious

● Lessons learned, later development of similar products, be sure to be prepared.