Oh no!

When the new deadline came closer more trouble happened. The industry production test of my drill bit holder worked perfectly. But it went really wrong when the actual production started.

Photo of casting beard
A massive casting beard.

Elastic shit
The first industry test moulds were successfully done in a rather stiff plastic and looked very nice. Now it turned out to be tremendous problems squirting in the elastic material needed. I was forced to quickly approve a costly remake of the plastic injection tool testing a theory of increasing intakes from 4 to 10 would make it work.

Time waster
Adjusting one thing changes another. At least it did work, they got the troublesome rubber into the mould but this presented new problems. It didn’t work to just rip of the casting beard. I had to individually cut off ten strings from each casting beard from over 5.000 units =50.000 cuts! This meant hours of extra work on top of my stupid paper sheet packaging solution adding even more time to the task.

Photo of residue
Not something you want to cut this many times.

Cosmetic challenge
Even with the massive casting beard they had to push in the rubber at maximum pressure. This led to lots of residue left on the products, especially from the casting beards. If you didn’t cut it properly, or even worse, ripped off the casting beard there would be a considerable amount of plastic crap hanging out. This was certainly not good enough and I had to trim the inside with a nail clipper. Not a thing you want to do 50.000 times when the deadline is only a few days away.

Now it was time to call in the big guys to sort this mess out.

Missing the deadline

Illustration of breaking pants.
Rushing production might result in material failure.

An earlier SNAFU* with the bastard advisor had delayed my progress. Now everything was rushed on to deliver in time for the retailers catalogue.

Just in time… NOT!
I was in a very tight spot. They released their catalogue twice a year and wanted my Gearfix drill bit holder in the next edition. But I was in the middle of developing it and could not guarantee it would be ready in time. In fact, I couldn’t guarantee anything.

Worlds best retailer
They were concerned of me rushing the development and told me about another invention they had last year. He had a very clever tool, but it was rushed into production. That resulted in material failure and they had to recall all units. It simply broke apart in the hands of the customers and the product got such a bad reputation it never recovered.
He ended saying -”Developing new products have to take its time. It’s better you aim for next years catalogue Martin.”.

Yep, I missed it
I even missed our next deadline by a few weeks. But it was about five months until the next catalogue so no one really bothered. However, not being in the catalogue from start turned out to have a negative impact later on.

*Situation Normal All Fucked Up