IEN: What are the major concerns facing the materials sector, and how can they be addressed?
Rouse: The price of oil as a direct and indirect element of raw materials is the number one problem currently facing the materials sector. Nevertheless, there is a tremendous amount of ingenuity employed, to do more with less or do things a different way.
IEN: What are the best-of-breed design tools used in developing today''s new materials? How are they utilized?
Rouse: Modeling is the best and most economical means by which to begin development of products today. These tools help reduce the cost and time to bring a product to the marketplace.
Since tires are a "life and limb" product, our customers are very cautious with their developments and require extended time to qualify products, thus adding to the development cycle of new components. (Lab technician Larry Pelter is shown here tenderizing a polyester tire yarn to improve the adhesion of rubber through the use of a custom coating.)
IEN: How much progress do you see toward integrating the different segments of product development -- design, engineering, manufacturing, supply chain?
Rouse: Performance Fibers has long utilized a Customer Linked Commercialization approach to product development, which gives the downstream parts of the supply chain a central place in the development process.
However, in the last few years we have implemented a Design for Six Sigma process, which forces consideration of upstream supply chain elements like raw materials and manufacturing early in the product development process, leading to products that are less variable and more robust processes.
IEN: What are the R & D hotspots? Which ones are closest to commercialization?
Rouse: With the demand for high-performance tires to match the performance automobiles that are coming out today, we need products that will meet the demands of these tires.
Our current DSP® (Dimensionally Stable Polyester) family and the new products we are developing in this area are designed to meet the demands. These products extend the performance envelope of PET, allowing it to be used in the carcass of ultrahigh performance tires and as a cap ply reinforcement.
IEN: Will Product Lifecycle Management play an increased role in design? Why/Why not?
Rouse: Yes, product lifecycles are decreasing, thus causing more demand for faster approval and use. The old methods of development and approval will not meet these fast-paced demands. This is why we have to utilize fast-paced development methods. Performance Fibers works with our customers to identify the needs upfront and design our DSP® products to meet the customer needs.
IEN: How is testing and inspection technology keeping pace with advances in materials design?
Rouse: New tests and better testing equipment, supported by computer technology, is the only way to achieve the faster-paced process. We continue to add testing equipment to better ensure the quality and performance of our fibers. Our drivers are measurement of properties that predict downstream performance and inline measurement allowing improved control of processes.
IEN: What advances do you see in collaborative design?
Rouse: Experience has taught us that joint development of products is the fastest way to develop and get the right new product to the marketplace. As a technology leader in global industrial polyester fibers and materials, we are committed to working collaboratively with our customers on applications development.