A company that designs and manufactures conveyors sought our advice on reducing their production costs. They knew very little about roll forming and its limitations and advantages. There were several parts they wanted to produce more efficiently in order to remain competitive.
Most of the parts were simple channels that we could produce without issue. We designed and developed new tooling and began running the parts, reducing their production costs by roughly 30%. Other components were not so simple.
At first glance, their existing designs could not be produced any more cost effectively than they already were. For three days were met with their engineering and design teams. We were able to propose several changes that allowed for a more streamlined production of the parts. We made prototypes and tested our proposed changes.
The redesigned components could not have worked better. With working prototype assemblies and approval from management, we got to work on the new tooling and put together a manufacturing plan. This new approach continues to save them money and help beat their competition.