NGO: the washing unit reducing the industrial cost by 20%

NGO: 20% cost saving for a new concept of washing unit

After over 80 different washing units projects and over 250 moulds for tubs made for the most important washing machines producers, the Meccanica Generale decided to deeply tackle the need for continuous improvement by inventing a revolutionary plastic tubs, representing a real breakthrough in comparison with previous traditional concept.

 

 

Target:  

To create a completely new concept of tub for washing machines, resulting into a big cost saving, as well into a much better production efficiency.


Activity:

  •  New concept creation
  •  Patent application
  •  Prototyping
  •  Validation
  •  Serial production

 

Guidelines for development

Besides the obvious cost saving, the guidelines for the creation of the new concept have been also the improvements of any critical product/process aspects of the previous concept, as well as the design of environmental friendly solution.

The key aspect of the new washing unit, called NGO, is the choice of plastic material, which as been selected following the cost/performance ratio rather than the pure cost for kg. The use of high modulus material, together with design of small thicknesses geometry allowed to reduce the weight by 40% with same performances.

 

   The NGO concept

Three main components: front part (F), rear tub (R) and backplate (B)

The structural backplate incorporates the bearing housing and it is vibration welded to the rear tub, which represents the water container, completely flat inside.

The closure of the washing unit is obtained through a double vibration welding process: backplate structure (B) to rear tub (R) and rear assembly (B+R) to front tub (F).

Any critical area for the process of the previous traditional tubs (area with big thickness) has been completely redesignedm with even and small thicknesses.

 

Benefit of the NGO concept

The NGO washing unit is made in three parts instead of two: this might seem a paradox, but in reality, even with this additioanl part, the NGO washing unit can grant following benefits, if compared with a traditional one with same performances:

-40% plastic material: small thickness and high mechanical performance of the bottom obtained through the backplate welding allows a 40% plastic materials reduction.

-50% cost of counterweight fixation: the innovative "spring-screw" system patented by Meccanica Generale allows a saving of minimum 0,5€ for each washing unit.

Improved production efficiency: the NGO geometry includes completely re-designed areas which where critical with the previous concept, resulting into a much more reliable process, with higher quality index.

-40% injection: to produce the same amount of washing units, the NGO concept requires approx 40% less injection hours, on smaller injection machines.

 

Product and process validation

The developmenst of the NGO washing unit has been entirely made and financed by the Meccanica Genarele Group, including the manufature of prototypes with final injection technology, which have positively finished the mechanical life tests, according to STIWA standard.

Startng from June 2011 the NGO system is officially in the market and, at the end of year 2012 there will be over 2.5 millions of washing machines in the market with this new washing unit.

 

 

Awards

The NGO washing unit has been awarded by Indesit Company with the 2011 Innovation Award.