From 3D Design to Manufacturing
Our client required a muffler for one of their utility vehicles. They sent us a rough drawing of the geometry of the product, along with engine back pressure, noise and emission requirements and surface target temperatures. In addition, they requested a coating for their product that would withstand up to 1,600 degrees F. Our engineering team converted the drawing into a full 3D model, we conducted Finite Element Analysis (FEA) and Computational Fluid Dynamics (CFD) simulations and designed the product to comply with the client´s requirements. The result, a fully functional product that has complied with all the required technical, performance and quality standards. You might have been driving a vehicle with one of our products!
Manufacturing Process Improvement
Our client was experiencing quality problems with certain components of a zero-turn mower. The components were being manufactured by two different suppliers. One supplier was responsible for cutting and bending certain subassemblies, while the other supplier would weld the parts together to produce two identical final subassemblies. Our client was having numerous line stoppages due to metrology and presentation quality problems. Our solution consisted in improving the quality issues, thus reducing the overall assembly cost by reducing the assembly line stoppages altogether.
We successfully reengineered the part by reducing the number of components and therefore reducing the number of welds required for assembling the products. In addition, instead of airbeding, we proposed die-cutting the components and forming them using stamping machines to improve metrological accuracy. In addition, because we were controlling the whole process, we were able to control all metrology from the beginning and therefore deliver a zero-defect final assembly. You might have noticed a smoother ride while maintaining the lawn!
Our client was experiencing difficulties with their logistics from their Chinese supplier. Delivery times and consistency had become a problem coupled with increased shipping costs and inconsistent quality. Our client wanted to bring the manufacturing of certain material moving carts in-house, but they still had to outsource certain manufacturing and finishing processes. Our solution was to provide them with a finished product ready to ship to their customers.
We developed new bending tooling and welding fixtures and sourced certain specified components from their suppliers. We also matched the required specified coating and coated the final product in-house. By controlling, cutting, bending, stamping, welding, sourcing, and coating under one roof, we were able to solve their sourcing problem closer to home. We bet many of your purchases are being stocked on shelves using these carts at your favorite store!