Converting to Plastic
For one landscape equipment OEM, the conversion from steel to composite fuel tanks was an engineering, as well as financial, success.
Rugged, long-lasting parts as strong as steel but lighter in weight, quicker to assemble and less costly. That’s what enticed Jeff Reichert of lawn and landscape machinery company Finn Corporation, Fairfield, Ohio, to consider integrating plastics in the company’s line of straw blowers and HydroSeeders®, renowned among contractors for their sturdy steel manufacturing since 1935. Competing in a moderate growth market subject to the seasonal ups and downs of the construction and landscape industries, Vice President of Operations Reichert sought to increase profitability by cutting the amount of non-value added costs while maintaining the quality reputation Finn had earned over decades of solid performance in the field.
As part of a strategic manufacturing initiative Reichert termed “value engineering,” he and his team of engineers embarked on a course few professionals have the courage to take. “We took a step back from the process and examined our entire operation objectively, looking for opportunities to cut costs and strengthen our product quality at the same time,” says Reichert. “If that meant re-engineering our machines and our manufacturing process from the ground up, we were willing to do it.”
Timing is Everything
During that time, Bob Dunne, vice president - sales, for Meese Orbitron Dunne Co. (www.modroto.com), Saddle Brook, New Jersey, contacted Mr. Reichert with one such opportunity: using plastics to complement the steel designs. “We had been doing everything in steel and it had performed so well for so long that we never thought to consider anything else,” explains Reichert.
Dunne and his team of rotational molding engineers had designed and manufactured durable, plastic products and parts for OEM’s such as Toro, UPS and IBM. A founding member of the Association of Rotational Molders, MOD had been developing new products and converting existing products to plastic since the 1930’s, earning a slate of awards for excellence in design along the way. Reichert was immediately interested in Dunne’s success with fuel tanks. Rotationally molded into a single, uniform piece for structural strength and leak-proof integrity, the MOD fuel tanks eliminate fasteners, joints, seals, solders and welds that invite corrosion and weaken complex metal fuel tank assemblies. The potential for hazardous leaks and spills is virtually eliminated. Since they can be molded with tight radius curves, complex cutouts and an array of twists and turns in almost any shape, these tanks may be safely placed in vertical, oddly shaped and non-traditional locations, such as close to the engine or tucked under recesses in the body. This way, tanks can be designed to suit the existing machines and can feature increased capacity over metal tanks.
 After meeting with Dunne and MOD Sales Manager Tom Cooper, Reichert confirmed he could replace the fabricated steel fuel tanks with MOD’s rotationally molded plastic fuel tanks and cut costs while reducing weight, adding longevity and upgrading safety. According to Reichert, approximately one steel tank in two or three hundred eventually wears from inside due to the nature of the material and the type of care taken by the owner to avoid impacts. “But even one leak is too many,” asserts Reichert. “The tank should last the life of the equipment. Period.” MOD developed new, one-piece tanks for Finn’s T60, T90 and T120 HydroSeeder and B-40 Straw Blower that resulted in direct cost reductions ranging from 43% to 62% or better per unit. In addition, Reichert used this change as an opportunity to speed the assembly process and establish a commitment to historical retrofit, meaning any new parts had to fit existing machines already in the field in case a part needs to be replaced. That means the machines would not be materially altered and the MOD tanks would have to fit into existing configurations. One tank was shaped like a cheese wedge to fit into a triangular pocket inside the machine. Another featured four, molded-in inserts to affix the tank to the machine, replacing z-shaped, metal brackets and eliminating assembly time. “We set out to build stronger, safer tanks that also cost less,” adds Reichert. “The fact that we now have stronger, safer tanks that assemble faster and cost significantly less is just fantastic.” |
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Imagine the Implications
Once Reichert experienced these bottom line results firsthand, he saw tremendous opportunities to integrate MOD tanks and other parts throughout the product line. Recognizing Finn’s expertise lies in steel, he decided to invite MOD engineers in for an all day brainstorming session to review the entire product line and discuss where similar profits could be created. “It is very rare to find a company that is willing to open their entire operation to a vendor and freely discuss their goals and aspirations,” says Alan Girard, manager of engineering and quality assurance for MOD, who attended the session with Brian Muldoon, product development engineer for MOD and Jeff Stanley, value engineer for Finn. “I applaud them for coming to us with their plan and asking how we can assist them. We understand they know their business and they understand we know product design with rotational molding, which makes for a highly productive relationship.”
Reichert agrees. “This is a great partnership. We know our machines and where we want to make enhancements and we have a lot of ideas about where a plastic part might work. They can look at a part and say ‘yes this will work or no it probably won’t work’ immediately.” But just because a part looks ripe for conversion to plastic doesn’t mean it should be converted. “Before arriving at a yes or no answer, we want to understand what the part is doing, what kinds of conditions it needs to withstand, how much stress it will be under and whether it will be visible to the customer, for example,” explains Girard. “With the kind of access and information Jeff has provided, we have a solid understanding of their operation and can make our recommendations and our quotes much faster and much more precise.” One part Girard recommended against converting to plastic, for example, is a steel cover around a diesel engine. “It’s large and heavy, so it seemed like an ideal part to convert to the lighter weight plastic,” comments Girard. “However, an engine that powerful continually generates intense heat and most rotationally molded resins just won’t stand up to that over the long haul.” The typical heat deflection load of most engineered resins ranges from 300 to 400 degrees F while cross-linked polyethylene, often the material of choice in these applications for its strength and chemical resistance, withstands up to 200 degrees. Next Page >
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