Case Studies

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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Parts and Assembly Process

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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Improving Part Design

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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Risk Mitigation Project

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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Field Helps Customer Meet PPV Goals

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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TECHNICAL LINE REVIEW

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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integration success

RETHINKING THE ROLE OF SUPPLIER TECHNICAL SUPPORT  Challenge The Field Engineering team provides hundreds of line reviews, product tear downs, and other technical support services every year to identify cost savings for our customers. The challenge is getting the cost savings implemented because fastener/ fastening issues are generally a low priority.

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customer savings

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 an engine. The following observations were made with corresponding solutions:

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CROSS FUNCTIONAL TECHNICAL TRAINING BENEFITS CUSTOMER WITH A TOTAL SAVINGS OF $73,193 Observation and Solution Upon reviewing a customer’s request for a quote for new parts, a Field account manager discovered several parts being ordered had a special plating request. The plating requested was a high end organic finish that would provide a great resistance to corrosion, but would require multiple ...

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