Roof moulding is not able to consistently withstand the required force during pull out test.“ How to ensure the bonding strength between the surface of roof moulding body and end clip is sufficient to withstand the pull out standards required by customer ?”

• Meeting customer requirement• Increased customer satisfaction • Less defects and wastage• Increase productivity • Process become more efficient • Manufacturing cost is reduced

Problem to Resolve

Function Analysis

Cause & Effect Chain Analysis

Trimming

Engineering Contradiction

Physical Contradiction

Su-Field Model TESE

Contradiction Matrix

Separation, Satisfaction,

Bypass

System of Standard Inventive

SolutionsDynamization

Specific Inventive Principle

Specific Inventive Principle

Specific Standard Inventive Solution

T = [Funtion2 / (Problem + Cost)]

• Trimmed the glue component as the object is able

to perform the function itself.

• Glue is insufficient function in term of bonding the

body and end clips.

IF contact surface for bonding is small,

THEN less material is needed and the process cycle is short

BUT the bonding strength is weak and defective products are produced.

Improving parameters: Area of stationary object (#6), Speed (#9)Worsening parameters: Strength (#14), Productivity (#39)Manipulating variable: Area of contact surface for bondingResponding variable: Strength of bonding

#40 Composite Material Not to be considered as material specified by customer

#7 Nested Doll & #8 Anti Weight & #26 CopyingThe problems involves two simple components attaching each other during injection process, additional objects are not to be introduced.

#10 Preliminary ActionIt is irrelevant

#17 Another DimensionJoint surface can be maximized to include the top edge of the body part for additional contact

#14 CurvatureCombined with principle #17, curvilinear was added into the area. Curve shape needs less material, it gives better visual appearance

#3 Local Quality & #15 DynamizationInterlocking can improve the mechanical bonding strength

In our problem, the size requirement of contact area at the joint surface is the only parameter that develops a contradiction at two opposing values.

• Where need to be large? On the direct contact surface area for sufficient bonding.

• Where need to be small? Other surrounding surface area for less usage of material.

Inventive Principles : # 4 Asymmetry : (similar to #3 and #15)provide better inter-locking and improved mechanical strength at the contact surface

# 24 Use of Intermediary (similar to #10)this is irrelevant as glue as intermediary object which has trimmed

#1, #2, #7, #30 not considered as no other parts are to be introduced to the part assembly

• Trend of increasing Dynamization

Inventive Principles

#3 Local Quality

#4 Asymmetry

#15 Dynamization

F1 (Mechanical:

adhesion by glue)

Roof Moulding

Body

End

ClipsBonds

withS1 S2

Sub Field Model focus on the Zone of conflict where the contact between substance and field occur the overlapping of either useful or harmful.

F2(Mechanical: by structural locking)

Roof MouldingS3 (Modified S1)

End Clips(S2)

Bonds With

Before