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Customer Manufacture industrial louvers
Problem Customer was using an assembled ground piece for a shaft assembly.
Solution We changed the manufacturing process on a shaft extension from piece assembly, ground and pressed to cold heading.
Savings $8,850
 
Customer Manufacture luggage carts, shopping carts, etc.
Problem Axels rusting and breaking, resulting in costly maintenance in field repairs .
Solution We changed the manufacturing process of the part from ground and pressed to cold heading. The part became slightly cheaper, but the real difference was the field performance of the part.
Savings $2,500 in piece part cost. Savings in field repair (amount undetermined)
 
Customer Manufacture store displays
Problem Customer was using three different parts for a similar purpose.
Solution We worked with the customer and designed one part that would serve all three purposes.
Savings $56,000
 
Customer Subcontractor for 3M
Problem Customer was using serrated washer head to hold hanger bracket.
Solution We proposed using a standard head. The customer performed their vibration tests and the part passed.
Savings $21,000
 
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