A8 / FIXTURES
Challenge
A packaging line handling frequent SKU changes depended on machined aluminum nests with multi-week lead times, making every new product introduction a scheduling problem.
Constraints
- Nests must locate glossy consumer products without marking
- Line vibration and washdown environment
- New SKU tooling needed within one week of CAD freeze
Engineering approach
Nests were standardized on a printed glass-nylon base with product-specific TPU contact geometry generated from each SKU's CAD. Every nest is cataloged in the customer's part library with revision history, so line operators reorder replacements without engineering involvement.
Results
- Changeover tooling cost reduced by an order of magnitude vs machining
- New-SKU tooling turnaround within one week of CAD freeze
- Operators self-serve replacements from the part library