Making Products That Feel Right

Discover and diagnose inconsistencies in manufacturing processes

Overview

How do you make sure your assembly line keeps producing materials that ‘feel’ right? You may have hundreds of steps separating raw materials and your highly processed end-product. Numerous steps have a direct impact on the perceived quality of your materials. You could set very tight tolerances on each step to ensure that the result doesn’t vary in feel, but that’s expensive and unnecessary. Instead, you should measure the final product and identify how changes in process effect the final result. You’ll know what steps need to be controlled and can focus your attention – and money, fixing the steps that count.

Maintaining a constant “feel” is less expensive when you can identify the steps the count.

Project

A textile producer making denim was consistently selling to the luxury brands and tooled up to increase their production. However, their new production lines are being rejected by the luxury brands they’ve sold to because their new textiles ‘feel cheap’ but they don’t know why. SynTouch tests the products from the old line and the new one. Tested materials include both the final result and samples of the textile throughout the production process.

Process

SynTouch detected a difference in the feel of samples from their old assembly line and the new one – validating the concerns of the producer’s clients. Working with the textile producer SynTouch identified several key steps in the production process that might cause these differences. Samples were tested for these critical steps and the two production processes were compared.


Several samples of the produced textiles were measured at steps A, B, C and D. Clear differences in the relaxation (hover/Link cRX: Relaxation) and tactile stiction (hover/link fST: Tactile Stiction) were detected at steps C and D but only on the new assembly line. The feel of the materials changed the most between steps B & C.

Outcome

The textile producer was able to locate the production steps that caused the lower-quality feel and resolve it. The new production now feels indistinguishable from the old one, and only a small change to the manufacturing process needed to occur.

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