Case Studies

The Field engineering team proposes alternative system to address short comings of current design while creating 9.5% in savings.  Challenge During a technical line review at a prospective customer’s facility, Field noticed high volume parts with features that were driving the cost up. The thread cutting screws being used required a secondary operation to create the slot. During assembly, the ...

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Field Fastener- Fastening Solutions- Cost Savings

FIELD PERFORMED AN ANALYSIS OF THE TOP 10 HIGHEST REVENUE PARTS TO FIND COST DRIVING FEATURES Challenge When reviewing the top 10 highest revenue parts from a customer, Field noticed that there were certain features on the parts that were significantly driving costs up. In an effort to be more than parts, Field’s engineering team came up with alternatives to design out those cost driving features.

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Challenge Field received a request from a prospective customer that provides components to the automotive industry. The request was for two high volume components that are utilized to fasten several components in a passenger vehicle. The requested design was a high cost / proprietary design.

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Field engineering

During a technical line review at a prospective customer’s manufacturing facility, the Field engineering team observed inefficiencies with an assembly process. Here's how we helped solve them.

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Observations and Solutions During a technical line review of a customer’s facility, the Field team observed the components and methods of manufacturing used to assemble a railcar. The following observations were made with corresponding solutions:

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Cost Savings

Challenge During a technical line review, a Field engineering team member noted a signal light being produced used a separate right and left side end cap. Both end caps physically fastened to either side of the signal light, but an extruded hole prevented this from being done.  

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Challenge While at a customer facility, a Field team member observed that a percentage of double ended studs were exhibiting external strip out during assembly. This resulted in the entire sub assembly having to be scrapped.

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Challenge The Field team informed a customer of the high risk of internal hydrogen embrittlement on a series of grade 12.9 zinc plated socket head cap screws which they were using in electric motors. These parts had seen failures in the past, and going forward Field did not want such risky parts to be used anymore.

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THE FIELD ENGINEERING TEAM SUGGESTED AN ALTERNATIVE MANUFACTURING PROCESS RESULTING IN A PIECE PRICE SAVINGS OF $33,310 ANNUALLY.  Challenge Field received a request from a current customer to provide a quote for an expensive kit that contained four pieces of a stainless steel custom fastener with a “D” shaped head.  The kit was identified as an item that needed to be supplied at a lower cost.

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DIAPHRAM ASSEMBLY AND HOT FORGE REDESIGN

ENGINEERING REVIEW AND PART REDESIGN YIELDS $75,390 PIECE PRICE SAVINGS Challenge During a technical line review at a prospective customer’s facility, the Field engineering team observed a cumbersome and time consuming assembly process to a three component diaphragm. Upon further evaluation of the part, the Field team discovered that the manufacturing process to make these components was costly ...

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Challenge During an assembly line review with a potential customer, the Field team noticed that a considerable amount of meter boxes were being scrapped and removed each day. Upon further review of the assembly process, the team observed that the workers were having problems with tapped thread quality and recess damage.

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Audit Customer Savings

Challenge During an internal lean audit at Field, a team member was reviewing the frequency of transactions associated with a small group of fasteners being used by one customer. The team member discovered the number of transactions was inconsistent with the value of the product. The customer was managing a Kanban program internally and was shipping low dollar items on a regular basis and ...

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