Video courtesy of Northern Power and Safety Solutions
Introduction
Northern Power and Safety Solutions approached us a year ago with a challenge: to mass-produce a lockout tag that not only met workplace standards but also featured a modern, aesthetically appealing design. Bryan, the tag’s creator, came to us with an initial design that focused primarily on functionality but needed refinement to enhance both its appearance and its durability for mass production.
Challenge
Bryan’s initial design had potential, but it needed several changes. The lockout tag, which was a critical safety component for industrial environments, required both aesthetic improvements and technical modifications for mass production. These included:
Design refinement: The design was functional but needed to be improved for visual appeal. The hinge mechanism, in particular, posed a challenge.
Mass production considerations: The aim was to scale up production without compromising on quality or design integrity.
Functional requirements: The tag needed to withstand tough working conditions and handle elements like wear and tear, exposure to chemicals, and heavy usage in industrial settings.
Durability: The tag had to be resilient, including its color quality and longevity, and support features like a QR code for digital access.
Our Approach
Design Review & Initial Challenges: Bryan’s tag design was unique, featuring a living hinge system with circular pieces connected by a shaft. This was a first for us, and the hinge required tight tolerances to function correctly. We encountered several design challenges requiring many revisions, primarily centered around the precision of the living hinge mechanism.
Collaboration and Iteration: The initial phases of the project involved a lot of back-and-forth communication between our team and Bryan. We worked closely to refine the design, providing feedback and suggestions to improve functionality and appearance.
Color Specifications: The design required the tag to be produced in white with red lettering for visibility and safety. This posed challenges in ensuring color consistency in mass production.
QR Code Implementation: The inclusion of a QR code on the tag proved to be a difficult technical hurdle. Our team explored several options for integrating this feature.
Complications & Solutions: As production progressed, several issues arose that required innovative solutions:
Resin Bleeding: One of the major complications was resin bleeding. During production, this led to poor adhesion of the QR stickers, causing them to peel off or fade over time. Bryan received negative feedback from his customers, which prompted us to address the issue.
Post-Processing & Testing: To fix the sticker adhesion issue, we explored various post-processing techniques. We experimented with different coating solutions, attempting to find the optimal material and method to ensure the stickers remained durable and did not fade or peel.
Final Solution: After testing multiple approaches, we found a successful solution by printing the QR code directly onto the part itself, rather than using stickers. This eliminated the issue of peeling or fading caused by resin bleeding.
Results
Functionality: The final design met all the functional requirements. The living hinge system worked perfectly, even with the tight tolerances, and the tag could withstand heavy usage without compromising its integrity.
Durability: The direct printing of the QR code addressed the previous issue of stickers fading or peeling. The result was a lockout tag that not only looked better but was much more durable and long-lasting in the field.
Aesthetics & Production: The final design met Bryan’s vision for a more aesthetically pleasing and professional look, while also being manufacturable on a mass scale.
Conclusion
Working with Northern Power and Safety Solutions was an excellent example of how close collaboration and innovative problem-solving can lead to a successful product. Through multiple phases of design, testing, and iteration, we were able to turn Bryan’s initial concept into a refined, durable, and mass-producible lockout tag. By addressing the critical issues of hinge precision, QR code functionality, and sticker durability, we ultimately delivered a product that met tolerances while also providing a modern, professional appearance.
This project underscores the importance of ongoing feedback and testing in product development and highlights our commitment to delivering high-quality solutions even in the face of challenging production hurdles.