THERMOFORMING EXPERTS

SAY PLASTICS, INC.165 OAK LANEMcSHERRYSTOWN, PA 17344

PH: (717)-633-6333WWW.SAYPLASTICS.COM

THERMOFORMING CASE STUDY

MATERIAL HANDLING

Case Study Material Handling

When Harley-Davidson Custom Vehicle Operations needed a material handling solution they called SAY Plastics.

SAY PLASTICS, INC.165 OAK LANEMcSHERRYSTOWN, PA 17344

PH: (717)-633-6333WWW.SAYPLASTICS.COM

Case Study Material Handling

CUSTOMER:

Harley-Davidson Motor Company, CVO

Returnable dunnage system for management of finished chrome wheels.

Design, develop, and manufacture custom material handling system.

APPLICATION:

CONTRACT:

SAY PLASTICS, INC.165 OAK LANEMcSHERRYSTOWN, PA 17344

PH: (717)-633-6333WWW.SAYPLASTICS.COM

Case Study Material Handling

Chrome wheels provided by Alcoa ASL of Chillicothe, OH were being packed onto a wood pallet with hand made plywood and 2 x 4 dividers, then wrapped in foam and shrink wrapped.

PROBLEM:

ISSUES: Waste: When received, the shrink wrap and foam was single use and had to be disposed.

Labor: Additional time was required to inspect and pack the wood materials prior to returning.

Safety: The weight of the wood dividers made it necessary to utilize two people during handling. In addition minor injuries were incurred through nails and splinters.

Quality: Due to the packaging wheels were more susceptible to scuffs and scratches.SAY PLASTICS, INC.

165 OAK LANEMcSHERRYSTOWN, PA 17344

PH: (717)-633-6333WWW.SAYPLASTICS.COM

Case Study Material Handling SOLUTION: SAY Plastics designed and developed a clean,

efficient, and economical handling system utilizing custom thermoformed tray dividers and stock plastic pallets and top caps.

VALUE: SAY Plastics developed an ingenious method for permanently adhering a closed cell foam into the tray divider wheel location during the forming process. Additional features included an interlock design which allows the divider trays to lock into a cube for stability during transport, while utilizing the stock pallet and top caps permanently attached hold-down strapping mechanism.

SAY PLASTICS, INC.165 OAK LANEMcSHERRYSTOWN, PA 17344

PH: (717)-633-6333WWW.SAYPLASTICS.COM

Case Study Material Handling

CONCLUSION:Harley-Davidson and Alcoa ASL saw immediate benefits in labor, safety, and quality by replacing costly expendable packaging materials, with a light weight, durable, material handling system, which paid for itself in less than 5 turns.

SAY PLASTICS, INC.165 OAK LANEMcSHERRYSTOWN, PA 17344

PH: (717)-633-6333WWW.SAYPLASTICS.COM