Issue #21 - Utilizing Process Optimization

November 22, 2016

LORD Corporation Uses Process Optimization to Enhance Structural Adhesive Technology

by Bob Zweng, LORD Corporation Central Regional Sales Manager &
Matt Ryan, LORD Corporation Sales and Distribution Manager

Process Optimization is an important function to consider when integrating structural adhesives into the fabricating process. The correct application of Process Optimization can help a manufacturer meet goals for structural adhesives utilization. Optimizing the design and 

fabrication processes are important steps in the successful transition to using structural adhesives as a bonding method. Process Optimization ensures the conversion to adhesives is done right the first time and addresses problems before they occur. The support services provide equipment selection and set-up, design assistance, workflow, and personnel training.

The correct application of Process Optimization principles can deliver several benefits that can help you meet your goals for structural adhesives utilization. These benefits include:

• Improved product and/or process design

• Reduced lead times

• Reduced design changes

• Reduced production and/or delivery errors

• Improved reliability

• Reduced warranty claims

• Risk management

• Reduced through-life costs

• Ability to manage and afford change

• Improved organizational structure.

The Process Optimization Plan 

The Process Optimization procedure begins with a dialogue between the customer and the adhesive supplier to define the customer’s needs and requirements. This first stage explores current processes and cost drivers, and prioritizes goals and future needs.

Once the customer’s needs and goals are documented and prioritized, and the current process has been reviewed, the adhesives supplier works with the customer to outline the process for the new structural adhesives system. A plan for implementing structural adhesives into the production environment will be outlined.

Testing is an important aspect in the implementation of a structural adhesives system. In-plant trials allow customers to experience the benefits of using LORD adhesives compared to the customer’s previous joining methods. Testing with various substrates, adhesive formulations, fixturing methods, and surface preparation techniques will ensure the best output. The final step in the Process Optimization procedure consists of installing equipment, training the customer’s personnel, and completing test trails.

One of the prime objectives of Process Optimization is to help the customer understand the working concept of a structural adhesives system – wherein one job function directly relates to and affects the next job function. This is where education and training become important. Each worker must understand how their job task, if done properly, will make the entire operation successful and produce a good product. Conversely, if one task is not handled correctly, it will negatively impact the final product outcome.

For example, if a component is not cleaned and prepared properly, it can affect the adhesive’s bonding properties. Components must move seamlessly throughout the bonding process, to ensure a properly bonded finished product.

Supplying the Services

Process Optimization services is an ideal way for a company to reap the benefits of both structural adhesives and an optimal production plan. Almost any company interested in switching to structural adhesives can take advantage of Process Optimization, including:

• Customers who would like to change over to adhesives but are concerned implementation might be costly or too difficult

• Customers who currently use adhesives but are interested in upgrading, modernizing, or improving their systems

• Customers who need to show added value to increase, maintain or acquire business.

At LORD Corporation, an emphasis is placed on the value of using Process Optimization to enhance structural adhesive technology. Incorporating adhesives into the design and manufacturing process not only offers the advantages of better quality products, improved aesthetics, and increased performance, but also provides benefits of reduced labor and expanded throughput. As an alternative to mechanical fasteners or welding, structural adhesive bonding offers the capability to build better products faster, more simply and at less cost. LORD technicians show customers how to create work instructions for each task, how to design and use fixturing equipment, and how to determine when a bond is done correctly.

LORD Corporation has over 40 years of experience in developing and manufacturing structural adhesives that offer superior performance and durability. Their extensive line of acrylics, epoxies, and urethane adhesives improve appearance, strength, and total cost savings. LORD Corporation is a leading supplier of adhesives in the transportation, consumer products, defense, general industry, and power industries, and an integral partner in Process Optimization.