Case Studies

Automotive Industry


 

Oil pump

Benefits 

  • Parts count reduced from 32 to 12 ( a 62.5 % reduction)
  • Assembly cost reduced by 79 %
 

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Motor coach Industries 
- QFD

Benefits

  • Time to market reduced from 5 years to 3 years
  • Large ‘wish list’ translated into tangible and measurable design parameters
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Motor Coach Industries
- DFA
 

Benefits

  • Part reduction from 4730 to 2210 
  • Improved installation time - 62 hrs down to 17 hrs.
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Aerospace Industry


 

Avionics Rack
 

Benefits 

  • Modular construction enabling multi tasking and easier installation 
  • 80% part reduction 
  • 31% fewer build days 
  • 19% fewer labour hours 
  • 47% reduction in structure weight 
  • 1 mile of wire less 
  • Total saving of $54,000 per aircraft 
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Contactor

 

Benefits

  • Parts count reduced by 65%
  • Before redesign - 402 parts
  • After redesign -137 parts..
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Cockpit / Cargo liner

Benefits

  • Elimination of 3700 fasteners. 
  • Reduction in assembly time of 3000 hours.
  • Redesign options explored and compared quickly
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Domestic and General


 

Electric Shower

Benefits

  • 32% parts reduction 
  • 23% potential reduction in assembly time
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Door chime

Benefits

  • Cost of battery version reduced by 22%
  • Cost of AC version reduced by over 40%
  • New design suitable for automatic assembly
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Weighing scales

Benefits

  • Rationalised into a single product 
  • Parts count reduced by 50% 
  • Assembly reduced by 45% 
  • Improved appearance 
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Scientific Equipment & Sensors


 

Grating arm assembly

 

 
 
 

Benefits

  • Part count reduced by 76 %. (from 39 to 9)
  • Assembly Cost reduced by 87%.

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Fluid level sensor

Benefits 

  • Parts count reduced by 75% 
  • Assembly cost reduced by 55% 
  • Simplified installation 
  • Reduced envelope size 
  • Increased use of standard parts
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