Paper Pro Punch Manufacturing Analysis - Case Study Example

Manufacturing Case Study QUESTION A. Function: The primary function of ‘Paper Pro’ punch is to make holes in the papers so that the papers are tied and attached. B. Aesthetic: It is of even color, generally ‘Paper Pro’ punch is found in black or silver color. The object is quite heavy and it weighs around 1.8 pounds for a 3-hole punch. C. Compliance: The organization ‘Paper Pro’ is government registered and the product 3-hole punches is available in EMI scheme (Paper Pro Inc., “Home.”). QUESTION 2 The 3-hole punch of ‘Paper Pro’ is very heavy in comparison to its volume. Thus, it is not very portable to carry in the pocket. However, there are also some of the punches that are made up of plastic and are comparatively lighter in weight (Paper Pro Inc., “Home.”). QUESTION 3 The 3-hole punch of ‘Paper Pro’ is very strong and heavy. However, in the process of punching papers up to 20 pages, the user exerts a lot of pressure. This may damage the lever of the paper pro hence it should be made stronger to withstand the force. Besides the lever, the punches also exert a physical pressure. This part is also required to be stronger. Moreover, the extreme humidity may also damage the same by the formation of rust throughout the metallic body of the tool. However, there also some of the punch tools that are made up of plastic, especially the lever (Paper Pro Inc., “Home.”). QUESTION 4 The product generally stays in the normal room temperature and humidity. However, with the extreme humidity it might rust its surface. It generally stays in the hands of users therefore the presence of moisture in the hands might also form rust. Moreover, it is also observed in the table or shelf of an office or an educational institute or in the living room (Davis 1-58). QUESTION 5 The parts that are more vulnerable to be damaged after the execution of physical pressure are the punches and the lever. These parts are directly connected to the body of the punch machine and with the holes of the same. It is also connected with the part of the instrument, where the pressure is exerted (Davis 1-58). QUESTION 6 The inside dimensions of the lever and punch are very important aspect for a punch machine to be effective. The proper dimension of the lever for the satisfaction of the customer can be achieved by exerting less pressure for making paper holes. Moreover, the proper dimension of the punches is also important as leads to the formation of the holes at the specific dimension in papers (Davis 1-58). QUESTION 7 There are also certain non-dimensional attributes that are required to be considered. These include proper smoothness and color throughout the body of the tool. The body of the tool is also required to be designed as per the segments of the customers. If the tool is used in the corporate offices, it is desirable to have a corporate look. Further, if the tool is used by a young boy or a girl, it is required to be designed accordingly (Davis 1-58). QUESTION 8 The material that is used in the punches and in the lever is generally of steel. Steel is one of the strongest alloys of the world. However, in the punch tool it is desirable to make punches and lever of stronger quality. Also another concern is the formation of rust in the body on those parts due to extreme humidity. The steel body of the lever and punches can be prevented from galvanizing of the same and the coating of the same with zinc paint. However, if the lever parts are made up of plastic, it is desirable to be replaced by steel (Arch Media Group, “Metal Coatings”). QUESTION 9 The basic process of strengthening the lever and punches part is by using harder steel in the process of making these parts. Moreover, it is also to be noted that to strengthen the steel several factors are taken into consideration. In this regard, if the heated steel cools down at a very slow rate, then the steel would be stronger. Besides, another aspect is the galvanization of the parts to reduce the corrosion of the same for greater effectiveness. In the process of galvanization, the steel is dipped into the molten zinc. This results into the formation of zinc-oxide layer in the surface of the parts. After this special zinc paint is also applied to the same to prevent corrosion (Sharma 1-113). QUESTION 10 In the process of making a better hole punch tools, the steels that are received by ‘Paper Pro’ are more strengthened. These steels can be used to make the final parts of punches and levers. These steels are now required to be galvanized and hence, make the punches and the levers corrosion free (Sharma 1-113). QUESTION 11 The products, which are having plastic as the material for making the lever parts should be replaced by steel. The steel are also required to be molded accordingly by the molder. Then there is a need to galvanize the same for the purpose of making a corrosion free levers and punches. For the purpose of galvanizing the parts, there are certain materials that are mandatory. These are molten zinc and special zinc paint. These materials are also required to be in an adequate manner for better quality control (Sharma 1-113). QUESTION 12 In the process of the making steel lever, there is a requirement of molding of the pieces of the steel in accordance to the requirement. This would lead to a proper shape of the lever and so also the adequate strength to the same. Moreover, the process of galvanizing the steel parts of the punch tool is regarded as a secondary approach. The secondary approach needs to be considered for adequate galvanizations of the same. In this step the corrosion free parts can be more adequately done by painting the same with special zinc (Sharma 1-113). QUESTION 13 The finishing process includes decoration of the corrosion free steel body of the punch tool. This should be decorated accordingly to the preferred segment of the customers. The steel body of the lever is required to be properly striped so that the product gets the appropriate design. It also includes proper packaging of the punching tool, so that the product does not get damaged on the delivery process (Sharma 1-113). QUESTION 14 This type of modification of the product is equally applicable for all the possible product lines of the organization. The molding of the steel and galvanization of the same can be done in a large number. Moreover, the complete body of the punching tool can be steel made and galvanized. For producing a large number of these types of modified products, more number of molders are required and also a large system of galvanizing of the same is required (Sharma 1-113). QUESTION 15 For the production of the steel lever, there is a requirement of large numbers of injection pellets for injection molding so that the lever are into perfect shape that are convenient for the user. It also requires bar stocks at large number for producing 10,000 lots of steel pieces. Besides, these it also requires metal ingots for casting of the lever pieces and the whole body into perfect pieces. QUESTION 16 There are certain environmental factors that are also required to be considered. There is a possibility for the formation of toxic by-products from the manufacturing process of the punching tool. However, this can be addressed by proper recycling of the by-products. Moreover, if there is any kind of harmful gas that is produced during the process, it also needs to be minimized (Jain and Chitale 1-835). QUESTION 17 The paper punching tool after the modification should be made completely of steel for environmental concerns. This is unlike in case of the plastic lever, which may affect the environment. However, the new product made completely of steel, would in no case harm the environment after the sale is over. This steel made punching tool can be recycled and hence, would cause no harm to the environment (Bhardwaj 1-313). QUESTION 18 The operational process through which the finished product is produced is shown in the following steps: Setting up of the bar stocks for cutting the steel pieces Molding of the pieces into appropriate shape through the molder Casting of the same into the desired design Perfect color and dimension and other aspects of the punching tool is applied Applying decorations to the punching tool Final inspection of quality check is being considered Proper package of the final product QUESTION 19 Assembly chart format Cutting of the Steel Pieces Molding of the Pieces Casting into Desired Design Color and Dimension Decorations Quality Check Package QUESTION 20 From the assignment, it has been learned that from the identification of an issue of a product and from discovering the steps through which these issues can be resolved, the product development takes place. The product development would lead to competitive advantage as well as long term sustainability of the same. Works Cited Davis, Joseph R. “ASM Specialty Handbook: Tool Materials.” ASM International, 1995. Print. Sharma, P. C. “A T.B. Of Production Enginerring.” S. Chand, 1999. Print. Jain, K. C., and A. K. Chitale. “Textbook of Production Engineering.” PHI Learning Pvt. Ltd., 2014. Print. Bhardwaj, B.P. “Handbook on Steel Bars, Wires, Tubes, Pipes, S.S. Sheets Production with Ferrous Metal Casting & Processing.” Niir Project Consultancy Services, 2014. Print. “Home.” Paper Pro Inc. 2014. Web. 26. Oct. 2014. “Metal Coatings.” Arch Media Group. 2014. Web. 26. Oct. 2014. Read More