Innovation in manufacturing is a journey, not just a price negotiation. I’ve experienced this first hand when developing a blown film extrusion process for layflat films. After successfully implementing it for one company, I designed an even more advanced process for another.
The project was on track—until top management cost-cutting decisions changed everything in the last minute before signing the purchase order. The original design included a high-performance rotating haul-off system, essential for roll to roll flat film quality. But to push the total machine price below $3M, it was replaced with a lower-cost version costing only 1/5 of the high quality haul-off system. The technical design team (including me) was not informed about this change, it only became apparent, when the machine was delivered and the technical design team was asked to start it up.
When production started, film quality issues arose. The blame? Shifted to the design—despite the fact that key features had been removed due to cost cutting. Adding to the challenge, the newly hired plant manager, having its eyperienxe from producing shopping bags, opted to use a smaller 400mm extrusion die instead of the recommended 800mm, further affecting quality.
The irony? The unused expensive 800mm die was later sold off for scrap metal.
This experience reinforced a crucial lesson: Cost-cutting without technical insight can turn a state-of-the-art investment into a liability. The right balance between budget constraints and process integrity is key.
💡 What’s your take? Have you seen innovation suffer due to short sighted saving ideas?