Executive summary To produce the three pin plug, the manufacturer first analysed the properties of different materials, the cost-effectiveness of different manufacturing methods, and the cost-effectiveness of the design and assembly line to optimise production and the marketing of the 3 pin plug. Urea formaldehyde was the best material used to manufacture the plug cover and base and brass were suitable for making the pins. Urea formaldehyde has good dielectric properties, has good thermal resistance, does not break easily and is cheaper than other resins in the family of amino resins. On the other hand, the weaknesses in the previous manufacturing layout of the process was labour intensive and very expensive, it was necessary to make a new layout design to substitute the old layout. Automating the new design made it better, cheaper and easier to assemble parts of the plug together to meet the two million plugs per year. The study showed that when the plug came to the end of its life, most of the materials used to produce the plug would be recycled and reused to make new products for other uses. Introduction and Background The paper discusses the manufacturing processes and the materials used to manufacture the 3 pin plug. It is important to use relatively cheap materials to manufacture the different components to produce the standard 3 pin power plug to make sure the resulting product is cheap to allow a competitive advantage in the market (Dodiuk & Goodman, 2013). The study recommends the use of thermoset resins, which are plastic materials that are easy to mold into any shape that is suitable for the cover plastic part of the plug. Styrofoam or foam plastic is a commercial plastic recommended for use because it is light and has good thermal and electrics insulating properties (Wiyaratn & Watanapa, 2010). According to Dodiuk and Goodman (2013), the plastic does not shutter when it drops or falls down. The paper also discusses a new and better manufacturing process to replace the old manufacturing process. Manufacturing Process The 3 pin plug is made of three parts, which include the cover, live pin, natural pin, cord grip, base, and grip screws. The discussion about each part and the suggestions about the right materials to use in making the parts are the following. The Cover Here, the cover is made of a material that has good insulating properties to protect people from electric shocks. The candidate materials include wood, which cannot be used in its state because if used, it leads to environmental destruction. On the other hand, metals such as copper cannot be used because they are good conductors of electricity. However, plastic, which has excellent insulating properties, is the best material to use. The recommended plastic includes the family of acetals and acrylics. Acetals are highly inflammable, strong, tough, rigid, resilient, and have good thermal and electrical insulating properties. However, acetals are suitable for making bearings and gears. On the other hand, acrylics are suitable for sunglasses, cameras, and binoculars because they are easily coloured and are susceptible to damage from household chemicals such as gasoline. The best options to use are thermoset resins that belong to the class of urea formaldehyde. Despite the thermoset resins being not aesthetically appealing, their properties make them suitable for use in making insulating copper cables and for manufacturing the cover and