Zipper Pull
We came across a data from our production engineer that the workers assemble covers through zippers all day. With the Zipper pull being small, they either hurt their finger and bleed or the Zipper break often. The blood also takes down the quality of the covers.
We pushed for a Zipper pull and the production department built a hook for the workers to consistently zip-in the covers.
This also helps the end users when they want to the cover and gives a premium brand interaction.
FR Sock with Glass Fiber
During a design research session at the factory floor, we observed that the workers were handling the glass fiber FR Sock with naked hands. Handling glass fiber through out the day can result in intense itchiness and soreness to the hands and lungs.
The process was corrected after we pointed out and we are moving towards non-glass FR Socks with our design choices.
45° Mold
As we make grids perpendicular to the outside edge, the flow of the polymer creates air gap in the mold, resulting in irregular shots, and longer production cycle.
The proposal is to create the grid lines at 45° from the edge making the mold flow faster and better.