Case Studies

FIELD REDESIGN AND PROCUREMENT YIELDED $32,700 IN TOTAL SAVINGS  Challenge The Field team initiated an engineering review of a customer’s product that revealed a problem they were having with a specific part. The machined part was subject to occasional cracking, due to the notch-sensitive nature of parts produced by the screw machining process. Part dimensions needed to be largely maintained due ...

Challenge Field’s customer was facing strong cost pressures as the only domestic manufacturer of their electronic products. Based on recommendations from Field on similar products, the large number of brass inserts and machine screws were targeted for evaluation. The current injection molded parts were designed with 32 brass inserts in thread sizes from 2-56 up to 6-32.

Challenge During a plant Gemba Walk with a current customer, Field observed an assembly condition and took steps to perform an Applications Problem Solving and Assembly Line Review of their manufacturing process when applying tape to pipe plugs and pipe nipples.

OVERHAUL OF CLIENT'S VMI PROGRAM YIELDS COST SAVINGS OF $50,000 Challenge Looking to improve on-time delivery, and reduce customer involvement and time needed to manage their hardware VMI program, a prospective customer elected to engage in discussions with Field. Inefficiencies with on-site scanning and replenishment, and overall organization of the program were weak. This led to parts hoarding ...

PART REDESIGN AND PROCURMENT IMPROVEMENT YIELDS TOTAL SAVINGS OF $206,500 Challenge During a technical line review of a customer’s facility, the Field team worked with the director of purchasing to identify cost-reduction opportunities among high-volume parts. One element in particular drew their attention: a stainless steel window hardware part.

FIELD INITIATED ENGINEERING REVIEW AND PRODUCT REDESIGN YIELDS $170,000 IN COST SAVINGS Challenge Field initiated an engineering review of a customer’s application that revealed a high-cost component, which required multiple assembly steps and created potential quality concerns. Field provided engineering resources to redesign a more cost-effective part that lowered component costs, assembly ...

FIELD EXECUTED A SEAMLESS TRANSITION AND REDUCED PROCUREMENT TIME BY 90% Challenge A manufacturer of signaling devices had a muddled VMI system in place that had excessive inventory levels yet daily stock outs. The supplier had a 8,000 sq/ft in-plant store onsite that was taking up valuable production floor space. The damage included 1,500 part numbers in over 5,000 bins and 55 VMI stocking ...

FIELD REDESIGNS TOOL, YIELDS $47,400 IN SAVINGS EQUATING TO 10X THE COST OF THE FASTENER Challenge Unaware of any immediate product improvement opportunities, the purchasing manager of a prospective Field customer led the Field team onto the manufacturing floor for a technical line review of the facility. Field immediately identified a significant cost-savings opportunity at the first work ...

FASTENING REDESIGN YIELDS SAVINGS OF $44,470 MORE THAN 9X THE COST OF THE FASTENER Challenge A prospective customer approached the Field team with a request for a quote on a fastener.

Challenge During an engineering review of a customer’s facility, Field inquired about the assembly process of one of their most popular tools. During a ‘Fit, Form and Function’ analysis of the tool back in the Field lab, cost saving opportunities were immediately identified.

REDUCED SCRAP AND INCREASED PRODUCT PERFORMANCE YIELDS COST SAVINGS $22,080 Challenge During a line review of a customer’s facility, the Field team noticed a significant amount of product scrap at one workstation. Upon inquiring, the customer informed Field they were scrapping 40 units a day.

Challenge During an engineering line review of a customer’s facility, the Field team noticed a commonly used, but often unnecessary and expensive fastening method.