Custom-fit foam protects pad-mounted gear
PAD-MOUNTED GEAR (PMG): ROOF AND DOOR PARTS
PMG units are installed outdoors and must withstand harsh environments, making surface paint integrity — especially on roofs and doors — critical. In 2024, paint chips and scratches during handling and transport became a major issue, contributing to an overall DPU of 0.14. This resulted in significant rework and increased scrap costs. “The cross-functional team first implemented interim foam and tape protection as a short-term containment action, then developed custom-fit foam and edge protectors for long-term use and as a permanent corrective action,” said Venkitesh Krishnamoorthy, manager, quality assurance, PMG production. “These solutions were the result of great teamwork and close collaboration between manufacturing engineering, lean performance systems, PMG quality assurance, PMG production, and paint teams across all shifts.” The outcome was a 57% reduction in DPU and cost savings in COPQ, demonstrating how simple, physical protections can yield major quality improvements and help improve customer satisfaction.
Pad-mounted gear in Arizona is engineered to endure the state’s harsh environmental conditions.
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Volts & Jolts | Volume 68 | Issue 3
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