Sweet Smell of Success for Unilever and Omega Plastics

twist cap Lynx deodorant dispenser In launching its latest male grooming product Unilever contracted the UK's leading rapid plastic injection mould toolmaking and moulding company and GTMA member Omega Plastics

In its development cycle the twist cap Lynx deodorant dispenser was rigorously evaluated from a design for manufacture perspective early enough in the cycle to ensure that not only were the prototypes functional but that the investment of intellectual decision making was passed on through the mass production process. "It is easy to see why Omega retain their niche in the market" commented Mohammed Chopdat from Unilever "they simply focus their attention on the manufacturability of all the components whilst adding proactive and meaningful design advice which advances the rapid manufacturing process and ultimately culminates in time reduction and cost savings for the customer".

The project itself contained 3 main prototype tools which were completed for initial trials within 3 weeks from design freeze, the results led to the testing and initial samples being evaluated with confidence and the surety that the components could be produced in mass volume without further design changes. "The investment of our time spent with Omega was invaluable and the benefit to all was clear to see when the project was completed 12 months in advance of our original schedule" was the reaction of the Unilever programme manager Paul Sherratt. "Not only did they produce the rapid prototype tools but also they followed on with the 4 impression pilot tools and then sat with our European production toolmaker KTW and discussed the benefits witnessed throughout the project, in an open and fruitful manner"

Lynx/Ace Deodorant - Built with Rapid Tooling "Anyone can claim to manufacture the occasional tool in a rapid format" according to Omegas specialist tooling technical advisor, Peter Angus, "however very few bring the value added benefit which is witnessed through design to manufacture continually from ourselves which in this case accounted for cost savings in excess of half of the 10 million euro production tool spend. The catalyst for the success was evident during our early discussions with Unilever and Adrian Caroen, Design Director from London based Product Design company Seymourpowell".

"Rapid manufacturing is clearly not only about producing a single element quickly but also influencing the process sufficiently to allow the overall project to be launched ahead of our customers competition, which ultimately dictates market share" commented Omega Plastics Managing Director Dave Crone "and this project was another indication that despite the continued if somewhat misguided threat of cheap overseas manufacture, the lessons learned in producing the rapid injection mould tooling within 90 minutes drive of the Unilever plant were instrumental in a very successful partnership"