Rubber caps falling off Swiss school chairs? See how we assisted Embru-Werke AG in creating new screw prototypes, solving the issue, cutting costs, and lowering complaints.
The Challenge: "For a Handful of Screws"
It is highly likely that anyone who has attended school in Switzerland has sat on an Embru chair, given that 40% of Swiss classrooms are equipped with them. This popularity can be attributed to Embru's motto of providing "furniture for a lifetime."
The purpose of this anecdote is not to promote Embru, but to highlight the severity of a problem that arose when complaints started accumulating about their best-selling school chair. The issue was that the rubber caps on some of the chairs' feet were coming off. This might seem insignificant, but it became an important concern since school floors are typically clad with linoleum, which is difficult and expensive to repair or replace.
"At that time, we had some 50,000 of these chairs in Swiss classrooms. So, every complaint was making us increasingly nervous. Where did the problem come from?", says Markus Simitz, Purchasing Manager at Embru-Werke AG. After an internal examination, it was determined that screws were potentially the source of the problem, and that the rubber caps were coming off the countersunk screws when subjected to sustained force, such as when students leaned back in their chairs, which they tend to do.
The question remained: What should be done?
Let‘s ask Bossard, they have the equipment to test out alternative screws. Together, we developed half a dozen new screw prototypes, with the primary challenge being ensuring backward compatibility.
The Solution: Replacing the Screws, Not Parts of the Chairs
Following a series of laboratory tests, one of our engineers confirmed that the screws were indeed the root of the problem. This meant that the new screws needed to be compatible with the previously delivered chairs, their casters, caps, and 4.0 mm screw holes. The customer aimed to replace only the screws, without having to replace any parts of the chairs or the entire chairs themselves, as that would have incurred significant costs.
Once the new screws were in place, the problem was solved. "After three weeks of testing, Bossard finally delivered our new screw."
Customer Benefits at a Glance
Cost-saving: Embru saved a considerable amount of money by replacing only the screws instead of having to replace parts of the chairs or the entire chairs themselves.
Peace of mind: Complaints about the chairs have significantly decreased, and the customer now knows how to handle any issues that may arise.
Improved awareness: The experience has raised the customer's awareness of how fastening technology can help solve design problems, such as selecting the right type of screw. This insight has been useful in developing new designs.
Quality assurance: By investing in a high-precision computerized screwdriver, the customer ensured optimal results and avoided any issues caused by minor torque differences during installation.
