Production problems…we’ve all been there. Consider this: A new type of plastic was selected for an automotive headlamp component. Nothing else has changed in the manufacturing process—but it should have been. Now the water seal, an ethylene propylene diene terpolymer (EPDM) foam die cut laminated with pressure-sensitive adhesive, is not bonding to the new plastic and is simply falling off.
In another scenario, the materials for a new building insulation bonded perfectly for the first six months of use, and the new product was a hit. Then summer came along, temperatures began to rise, and the insulation materials started to delaminate and fall apart.