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Mutilation Protection, scuff, scrape, scratch, gouge, ISD, damage

From Concept to Reality

WHAT'S NEW !

INQUIRY

Mutilation Protection, ISD, Damage, scratch, scuff, gouge, scrape, WIP, reusable, expendable, dunnage, bins and totes

Molded Tubes to cover pipes and slide bars

AT Next we developed a unique heat molding process that allows us to mold our 6mm PVC coated lamination into rounded or squared tubes and 2 sided angles to fit the most common tube sizes used to assembly and WIP platforms.

These tubes feature a special acrylic coating so that you can add many of our surface tapes to add improved mutilation and handling features to these surfaces.

Our PVC wear tape allows parts to be slid along WIP frames, and our Fleece tape offers a class A friendly finish.

The tapes can be replaced over time lowering the cost of replacements. Perhaps more importantly this provides you with ways to insure your 5S programs remain in good condition, and also allows you to have clean surfaces during inspections.

Free space is a rare commodity. Storage systems that are designed in tight spaces, or engineered to maximise the number of parts they hold, can be problematic for employees to load and unload.

Next has successfully outfitted sequence centres, at both the load and unload sides, with protective covers. Made with CLASS A padded materials, our protective covers are removable, easy to clean and can be colour coded if desired. Now all entry points can have hard surfaces covered; safeguarding parts damaged by contact.

Areas of an assembly plant, which require mutilation protection are numerous and can include: work surfaces, posts, I-Beams, columns, tooling, and printer stands. Also, tool stands within a work cell or tight spaces, or where high processing volume occurs are also areas which can benefit from mutilation protection.

At Next we have created hundreds of custom designed mutilation protection products to reduce part damage for many clients.

Mutilation Protective systems for sequence centers, work cells, molding presses and assembly areas

Next adds assembly of plastic corrugated inserts, WIP trays, bin separators

We have upgraded our CAD cutting so that we can economically cut up to 10mm thick plastics, corrugated and foams.

We have added assembly stations equipped with PSA and Hot Melt bonding as well as heat bonding so that we can form plastic corrugated and sheeting into dimesionally stable WIP carriers.

Our assemblies can have XLPE dunnage added to them, spun bonded surfaces, XLPE surfaces and Micro Fleecce surfaces and edging.

We can cut to shape, lock and fit, screw in place, bond with hot melt, psa or heat and add Velcro hook and loop.

Next Adds Wide Range of DIY "Do It Yourself" Tapes, Wraps, Pads and Supplies

Next is proud to offer the BumpIT line of PSA protective tapes, self-fit padded wraps and pads, post guards and many other supply products. Now you can order samples, and purchase or RFQ supplies, to outfit your production facility with easy to use and install products. Visit our site "Do It Yourself" tab, as well as the tips and techniques guides on how to use our products for enhanced mutilation protection.

Clear reinforced PVC Tape to Repair Curtains

With the success of our BumpIT line of PSA protective tapes, our customers asked us to consider how they could repair clear rack curtains that have minor tears and cuts. Often caused by forklifts, protruding parts or tool cuts, these tears quickly expand in a short period of time and often require a complete curtain replacement. Once torn, or cut, curtains are no longer suitable for the job intended and leave parts, as well as the rack’s interior elements, unprotected.

Our curtains, specifically our 14oz, utilize a scrim that is 70% stronger than that of our competitors 13oz and 18oz curtains (see our earlier blog for more details), providing greater durability and service life. We are now testing a PSA tape version of this same fabric for use as a repair tape. This tape will allow you to quickly repair a curtain, bringing back its full functionality, as well as extending its service life, for significantly less than the cost of a new replacement. Our clear reinforced PVC repair tape will be available in the fall of 2017.

Addition of CAD based

Water Jet & Multi-Axis Machining

Next now offers XLPE foam or XLPE foam with PSA that is cut using a CAD-based waterjet system. This system allows us to manufacture, based on your specifications, perfect shapes and dimensions with greater precision each time.

We also offer CAD/CNC designed cut foam, from 4lbs to 8lbs, that is used for numerous dunnage requirements. Our CAD/CNC based 3 and 5 axis machining service can also create forms for assembly lines and presses manufactured from UHMW plastics, reinforced plastics, nylon, or steel. These precision crafted pieces are all cut from high-quality materials to meet your exacting standards. Our service offers a fast turnaround time to get your line up and running.

Unique to Next is our ability to cover XLPE foam with protective CLASS A surfaces to increase the lifecycle of foam products.

We can also combine cut foam with cut corrugated and expanded plastic, from 4mm to 10mm, to create unique trays and part holders for your production lines, and offer in-house assembly of these custom-made trays.

Mutilation Protective Tape

A BETTER Post Guard

PSA Lamination

Based on approved CLASS A materials we have developed a line of PSA tapes, suitable for mutilation protection. These tapes will provide your employees with products they can easily and quickly use to add mutilation protection to most surfaces, without stopping the work flow. We currently stock tapes in 2”,3”,4”,5” and 6” widths. Our first new product is a 2mm foam padded PVC plastic surface tape used for mutilation protection where impacts often occur; for example, inside rack edges, assembly equipment surfaces, or tables. This tape can also be wet cleaned.

Next is our micro fleece surface tape which is conformable to any surface and extremely durable. It offers CLASS A surface protection that can be used to improve mutilation protection in totes and bins, as well as tool and work surfaces. It can also be used to cover XLPE foam to extend its lifecycle.

We also offer a cushioned version of our micro fleece tape that has been designed to provide mutilation protection for fragile parts requiring an extra degree of padding. This tape can also be used to repair hanging bags where the padding has deteriorated.

Our PVC tape is acrylic coated and currently available in the following colours; black, blue, red and yellow. It can be used to repair damaged wraps and pads, or used on hard surfaces where a degree of abrasion resistance is required.

While these PSA materials are offered as economical tapes in widths from 2” to 6”, we also offer custom cut CAD/CNC services of the base materials to any dimension or shape you require. Do you have a fleet of racks, totes, trays that need resurfacing? We offer pre-cut pieces, manufactured to your exact requirements, in any volume required. These products can be applied on-site, within your production cycle, saving you time and the inconvenience of costly downtime.

Damage to parts often occurs during the loading and unloading process. Because our customer, like most manufacturers, uses metal racks for shipping he wanted a system of protecting parts during this procedure. Initially they used XLPE covers, placed over the rack’s metallic posts, but these were easily damaged and difficult to see, plus they quickly became dirty and were near impossible to keep clean.

We solved this problem by creating a unique laminated foam and plastic material that we mold into a brightly coloured fitted post protector. Assembly employees, forklift drivers and managers can easily see the guards, making sure they are in place when required and removed when they are not needed. Cleanable, lightweight, and padded post guards are available from our eStore.

Our lamination line is now up and running! Our new line allows us to apply PSA (Pressure Sensitive Adhesives) to a wide array of products. With PSA lamination, we can now produce adhesive tape products and laminate materials of different compositions together.

Combining our lamination line with our slitting, sheeting, and custom CAD\CNC cutting means we can offer a wide range of OEM approved products.

Separation Paddles: Redesigned To Cantilever With a torsion Spring

Moving fascia parts between molding and painting areas requires mutilation protection. Any scratch on a molded part will easily ruin it for painting, and scratches on painted parts require refinishing or disposal. To protect such fragile parts, we offer fascia bags that cover parts during WIP (Work-in-progress). However, bags require management; they not only require two employees to cover a fascia part but once removed bags must be stored, counted, returned to the last process, and then laundered as they become dirty. A torn bag also requires repair, and you should have an inventory of bags that match your process requirements. Plus, racks, with a fascia in the bag, are often over stuffed deforming the fascia and causing abrasions

To find a viable alternative to the fascia bag we examined older rack systems using padded paddles and discovered that these systems required significantly less management resources, the tradeoff unfortunately was that they did not provide parts with sufficient mutilation protection.

We thought we could improve on the padded paddle system and create a better one, and we believe we have.

We have designed a unique laminated foam and textile solution that we sew into a paddle. The paddle is designed to separate each fascia part, covering as much as 100% of the surface area. The paddle can be flexed and contorted to fit the fascia part when loaded on the rack, but becomes completely straight and folds out of the way during unloading. The paddles are semi-fixed to the rack, so every rack has the exact same number of paddles. Now you no longer need to worry about managing bags, cleaning, or storing them. Plus, you not only get improved part protection, significantly reduced maintenance costs, but plant space is freed up as you no longer need storage room for empty bags.

Next is proud to offer an in-the-box system of dividers and packaging products, developed by ITB Packaging, to our lineup. These products can be assembled and installed in our shop, or yours, to serve YOUR RETURNABLE AND EXPENDABLE PACKAGING NEEDS.

ITB Packaging’s revolutionary process uses less raw materials to perform the same function as other packaging manufacturers. This leads to lower prices and greener processes; less material means less manufacturing costs and a smaller footprint, while lighter weight means lower transportation costs. The process requires no tooling. Interior cells are sealed from top to bottom, providing strength, durability, and superior part separation and protection.

The divider’s design allows us to ship our products flat. This contributes to our greater shipping efficiency. Our products arrive ready, simply pop open and drop into your container.

We offer dividers in many flexible materials to meet your needs, including: Bubble wrap Paper Fabric (Blue Plush and LX 15025)

The divider frame (used for the Pop and Drop application) can be corrugated paper or plastic, or the divider can be connected directly to the container using a hook/loop application. To inquire about our expendable packaging and our returnable packaging capabilities call us at:

Next offers “In-The-Box” Packaging Solutions

Collapsible Tote Design: A Space-Saving Solution

Next has outfitted space saving collapsible bins with plush dividers. The system allows stackable bins to ship compartmentalized parts that are fully protected during transport; after use, the bins are collapsed for easy return.

When collapsed, and stacked 12 high, 400 full bins were reduced to the storage footprint equivalent of 30 bins, massively reducing the space required to store them. This system reduced return shipping costs, in-house storage space in two facilities, and provided mutilation protection on high valued parts.

Carbon Fiber Solutions: Better Than Class A Covers, Pizza bags

Carbon fiber molding is now all the rage. One of the unique issues of this growing field though is that some molders require pre-cut carbon fiber prepreg (pre-impregnated with resin) sheets for their process. Carbon fiber sheets prepared this way are typically stored in a freezer after cutting and before molding.

Recently Next created an innovative new packaging system to support a customer’s unique requirements for a returnable program. Our customer asked us to design a system in which 30 square foot sheets of plied prepreg carbon fiber (6-8 layers per ply) could be stacked, stored, frozen, shipped, restored, processed and returned, all within the same package. We called it the super extra-large carbon fiber pizza bag.

Using lightweight aluminum tubing, combined with woven polypropylene fabrics, Next created 100, 5-foot square insulated bags that were engineered to fit in a movable racking system. This allowed one manufacturer to store cut sheets in their freezer, and easily transport racks to the molder where the molder stored the racks in their freezer until needed. The insulated bags allowed the full racks to be taken to the process area to feed the carbon fiber requirements into the process. Employees could easily remove, return, and carry the bags like trays.

Covering Moving Conveyances With Mutilation Protective Covers

We produce an assortment of wraps, plates and products to cover conveyor lines, overhead conveyances, and shipping racks to reduce damage to parts during production, storage and transport. Using CLASS A materials over foam padding, these products are removable and re-attachable for maintenance access to machinery.

You can find a wide variety of these products in our eStore that you can easily customize to fit your application. We can also manufacture and install custom fitted parts as needed.

Next Offers Stronger PVC Clear Rack Curtains

Next offers a 14oz light weight PVC laminated clear curtain material that is superior to most 13oz, 18oz, and heavier curtains. Clear curtains on racks are a necessity that provide parts protection from the elements, while also allowing employees to see inside the rack.

The problem with clear PVC materials is that they are prone to fail early in the lifecycle of most racks because they tear where they are attached, such as at handles or along closures.

Next has addressed these concerns with a new material that is 70% stronger. We have also added stress seams, to improve tearing resistance, at attachment points. Our stronger material ensures a longer lasting curtain, thereby lowering the cost of replacement curtains and the downtime racks are out of service while curtains are being repaired.