The Use of Designed Experimentation and Supplier Involvement to Aid in Process Start-up

In an effort to eliminate asbestos reinforcements in their automotive auxiliary motors, Rogers Corporation and Delco Products (Div. of GM) worked together to develop a non-asbestos glass reinforced phenolic substitute. Upon initial process start-up, Delco Products suffered from high incidences of commutator cracking as the parts were demolded. While making the usual process adjustments temporarily alleviated the problem, the cracking reoccurred in an unpredictable fashion. In an effort to permanently eliminate the high incidences of cracking, a three-way joint designed experiment was carried out between Delco Products, Rogers Corporation, and Borden Industrial Resins. Four significant factors were identified which led to new raw material specifications, adjustments in molding conditions, and a permanent decrease in the incidences of cracking from as high as 60% down to 0.5%.