DSC Design & Engineering Case Study:
Designed and engineered two thermo-plastic covers, including resolving production issues. Both projects had tight deadlines
Razor Cartridge Cover Development:
In just three months, I designed and engineered a cartridge cover that seamlessly fit both 4-blade and 6-blade razor cartridges, despite their different dimensions. I then collaborated with a third-party manufacturer to produce and test the designs. Once finalized, I handed off the CAD data to DSC for production
The Challenge: Production cartridge covers for the new DSC 4 and 6 blade Razors were popping off
Here’s an example of how my design expertise saved DSC from significant additional expense. After production began, an issue with covers not fitting was discovered. The supplier planned a redesign, which would have delayed the launch by 6 to 8 months. However, by analyzing the 3D data, I identified the issue as a manufacturing process error, not a design flaw. This insight prevented an unnecessary redesign and testing phase, saving both time and money.
Final Outcome:
I managed the design, engineering, and testing, reducing development time, risk, and costs—all while delivering OTIF
DtC Razor Case Development:
The brief was to design a vacuum-formed case, engineered to reduce damage and prevent injury for consumer testers. It needed to withstand direct-to-consumer transit while remaining cost-effective. After building multiple prototypes to refine the design, I partnered with a vacuum-form supplier to produce the part in a production environment. Following several refinement cycles, the parts were ready for manufacturing design lock and moved into production.
Packaging Engineering:
Design 4 E-Comm, DtC, Sustainability, Quality Management. Spent 3 years in a Hybrid role supporting Dollar Shave club as both a Designer and a Packaging Engineer.
Engineering Challenges:
Overview: I learned about DSC's "Start-up Mindset" and E-Comm/DtC challenges. I applied design thinking to the business and led workshops to create new products and enhance the existing lineup.
The production vacuum form trays were flimsy and didn’t meet DSC expectations. The manufacturer planned to redesign and build new molds, which would delay the launch by six months. Upon examining the 3D data, I identified a misalignment in the die cut due to a processing error. By adjusting the process, I was able to ensure the trays met DSC standards, saving both time and money, and enabling the product to be released on schedule and within budget
Quality Management Case Study:
E-Comm/DtC Case Study:
Crushed Boxes of DSC Shave Butter arrived at the regional DC with damaged tubes. I designed smaller cases to minimize head space, prototyped them, and conducted ISTA 6 testing to validate the new design. The new case reduced costs by 22% and increased pallet efficiency from 30 to 40 cases.
Sustainability Case Study:
Ran a 2-year program to move DSC’s Shave Butter and Cream from an Extruded tube to a Laminate tube with PCR. This achieved a yearly cost savings of 126k and a 61% claim on pack for PCR. There by reducing DSC’s 350-ton reliance on virgin plastic.