A global manufacturer of safety equipment was producing a line of molded plastic safety eyewear that specified Phillips head screws as the hinge pivots in the folding arms. Installing the screws was a tedious process, and the proper torque was critical to the proper “feel” of the hinge. If installed too tightly, the hinges were difficult to open and close. If they were too loose, the eyewear would not remain secure and comfortable on the wearer. In addition, repetitive opening and closing of the hinges resulted in the screws loosening and falling out of the assembly. In this highly competitive industry, this manufacturer needed to reduce cost and improve product quality.
