Innovating for the sake of innovating is meaningless if the outcomes are not driving tangible results — improving the bottom line, meeting performance benchmarks, and advancing core values.
All too often, organizations feel the pressure to set the tone, adopt early and invest in the latest technologies. Of course, change agents are critical, and big swings can result in home runs, but they can also cause costly inefficiencies, such a required trainings or even adding complexities and steps to processes.
At Rahco Rubber, Inc., we have stayed focused and remained ahead of emerging trends for over five decades by embracing a seemingly straightforward yet powerful philosophy: fostering a culture of innovation.
Trends take shape naturally, and we know innovation should not come from the top down; it should be embedded in the DNA of your entire organization.
This means encouraging employees to think creatively, experimenting with new ideas, and challenging the status quo.
Establishing an environment where innovation is part of the everyday workflow can lead to new solutions for problems that may have been overlooked. This comes in the form of regular brainstorming sessions, rewarding creative ideas, or even structured cross-functional teams assigned to tackle problems.
When teams and the organization as a whole are ready for change — whether it’s new technology or refined processes — the shift can take place naturally and its embraced harmoniously.
In Rahco Rubber’s case, we produce high-precision molded rubber parts for the nation’s leading and most sophisticated OEMs. Our production must yield batch-to-batch consistency that adheres to customers’ exacting performance specifications and geometries that are held to fractions of a millimeter.
So, when the stakes are high, why change a perfectly working system?
In the case of critical water-industry diaphragms that our teams continue to manufacture in high volume, the idea of automating a successful legacy process that worked efficiently for years could be a futile exercise. All processes appeared to be running smoothly. Quality was high, costs were controlled, and the customer was happy.
Production involved multiple dedicated team members handling tasks that ranged from custom-engineered material formulations and rubber compound setup, press operation, and de-molding of the finished component to a precision slitting operation, boxing, shipping and everything in between.
The case for automation was clear, but how? Where? And at what cost?
Through collaborative evaluation of the entire production cell and every individual operational detail — from tooling, molding operations and in-process quality control to shipping — we determined that any innovation that could create a meaningful impact would require a seven-figure investment.
Meticulous tracking and analysis of data to identify opportunities for efficiency and resource optimization was not only necessary, but the creative vision from the teams operating a vertically integrated production cell was required to make the case for end-to-end automation and map the innovations needed.
By aligning cutting-edge rubber molding equipment, robotics, and flashless-wasteless tooling, waste was significantly reduced, cycle times improved, and manual labor was optimized.
Today, among many examples, a new horizontal press operates autonomously and eliminates the need for human intervention in tasks such as separating components from mold plates, cleaning, and preparing batches. Excess rubber and waste reduction is now over 87%.
Building on this success, the next phase involved robotics for external collection and precision slitting of finished parts. For instance, valves requiring a slit to maintain a ‘normally closed’ condition are now processed in an optimized secondary operation. This system autonomously aligns molded parts and performs precision slitting, boxing, and shipping preparation, achieving fully automated production.
The result is a streamlined production cycle that reduces waste, enhances sustainability, and allows skilled talent to focus on higher-value tasks at the lowest cost of ownership for our clients.
Innovation is a continuous journey, not a destination.
By embracing digital transformation, investing in the latest technologies, fostering a culture of creativity, and staying adaptable, companies can ensure they’re not only keeping up but also leading the charge in the next era of manufacturing.
The emphasis on harmonizing technological advancements with human creativity will define the future.
Of course, innovation is not about a one-time investment but rather about creating a mindset of constant improvement and agility.
The manufacturers that succeed are those who are proactive in seeking out new opportunities in a calculated fashion, experimenting with new ideas, and always looking for better, faster, and more sustainable ways to meet customer needs.
If you’re developing new products, facing performance challenges with existing ones or concerned about the materials in your current parts and their alignment to specification — Rahco Rubber can help.